10Training and Performance

10.1. OVERVIEW

Implementation of site-specific training programs is an essential part of amanagement system to verify that all employees understand the chemicalprocess safety hazards associated with their jobs and the precautions neces-sary to prevent unplanned incidents. All training programs need to be docu-mented, and a feedback system must be established for plant managementincluding an evaluation procedure to verify that the training program meetsplant management objectives for safe operations. The training programsshould be designed specifically for the various functions or jobs in a plant,such as technical personnel, chemical process operators, maintenance, super-visors, environmental, health and safety personnel, etc. Reinforcement of thetraining program is necessary. Therefore periodic refresher training coursesshould be included in the management system. It is also equally importantto provide a system whereby changes or new information and lessons learnedfrom chemical process accidents are always communicated to employees andincorporated into the training programs.

10.1.1. Scope

This chapter addresses the essential components of training programs toassure management that site-specific chemical process safety information andprocedures are being communicated to and understood by all employees tosupport safe operations. The plant examples and programs included in this

TABLE 10.1Operator Training Program

• Written job description that states the duties and responsibilities for the position and theexperience and training necessary to qualify for the position.

• Procedures to determine whether an operator has demonstrated the ability to carry out theduties and responsibilities of the position.

• Specified training periods for the position, including evaluation and final qualifications aswell as a procedure for tracking progress of the trainee.

• General orientation and initial training of new employees before assignment to chemicalprocess safety hazards. The general orientation should include instruction on general siterules and practices, safety procedures and emergency procedures.

• Classroom training for newly assigned operators on specific activities which include detailsof operating procedures and safety training. For personnel without an operating background,the basics of fluid flow, heat transfer, instrumentation, etc., may be included to provide afirm base on which to build.

• On-the-job training which includes equipment familiarization, operating data collection,actual equipment startup and shutdown, control and adjustment of operating conditions andthe application of standard operating procedure to actual conditions.

• Refresher training at appropriate intervals to include updated information on proceduresand MSDS, safe handling of the emergency procedures and accident reports.

chapter describe the formal training programs needed for various depart-ments in a plant, instructor selection, skills needed by employees, docu-mentation requirements, and performance evaluations. Most importantly,examples of plant programs illustrate the need to identify in the planningstages the specific technical training needed for each individual or job assign-ment.

10.2. DEFINITION OF SKILLS AND KNOWLEDGE

In the inceptional stages of planning, the plant's management system shouldaddress the variety of training programs that are needed and who shouldreceive the training, as well as the skills that will be required to perform thejob. Table 10-1 is an example outline that illustrates skills and knowledgethat should be considered when designing an operator training program.

10.3. DESIGN OF OPERATING AND MAINTENANCE PROCEDURES

Operating and maintenance procedures, together with job descriptions andjob safety analysis, provide the building blocks for the development of train-ing programs that communicate to all employees the chemical process safetyconsiderations and requirements for safe operations. Appendices 1OA, 1OB,

and 1OC are examples of plant training programs for operators, maintenance,and technical personnel.

10.4. INITIAL QUALIFICATIONS

Prior to the formal training programs for employees, assessments of em-ployees' skills and knowledge are needed for those employees working inareas or jobs that have potential direct impacts on operational safety. Theseassessments should be made prior to hiring, or during probation periods.They should also be made prior to an employee's transfer from one job orarea to another and if an employee's job performance is unsatisfactory (i.e.,repetitious operator errors, accidents, etc.).

10.5. SELECTION AND DEVELOPMENT OF TRAINING PROGRAM

The first step toward a successful training program is to determine whetherone is needed to improve process safety. Sometimes, engineering or processchanges might be more effective. Training programs should be developedfor process and engineering, and these training programs should include anobjective-based lesson plan that clearly describes (1) the purpose/objectiveof the course, (2) each activity within the course, (3) the major topics to becovered within each activity, (4) the time requirement for the course, and(5) each individual activity and audiovisual requirements. Impartial observersshould attend all training courses to evaluate their effectiveness. Appendix1OC provides a systematized approach for the development of criteria forthe training program for technical staff. Appendix 1OD is an example ofestimating the costs for implementing a maintenance training program.

10.6. MEASURING PERFORMANCE AND EFFECTIVENESS

Evaluation of the effectiveness of training programs is needed to ensure thatthe training program is both cost effective and contributing adequately tosafe operations. It is equally important to provide a feedback methodologywhereby training programs can be strengthened. The evaluation processshould measure the performance of the student, the course, and the instruc-tor. (See Attachment 2 of Appendix 1OB for an example of measuring theeffectiveness of the training program for specific maintenance tasks. A similarperformance and effectiveness system for operator process safety training isprovided on page 212.)

10.7. INSTRUCTOR PROGRAM

Selection of instructors is critical to the success of a training program, whetherthe individual is either an employee who delivers training programs on afull- or part-time basis or if it is a qualified employee who has received a"train the trainer" course. Appendix 1OE is an example of one plant's criteriaused for instructors.

10.8. RECORDS MANAGEMENT

Documentation of training is needed for the following reasons:

• To comply with regulatory requirements• To measure the effectiveness of the program• To measure the performance of the employee• To satisfy the management system's need for verifying that all em-

ployees have been trained• To establish time and needs for refresher training• To provide a basis for evaluating the needs for updating or improving

the training course• To maintain auditable records (to show employee's name, instructor's

name, type of training, course contents, date of training)

Examples of documentation standards are presented in Appendix 1OA andAppendix 1OB.

10.9. ONGOING PERFORMANCE AND REFRESHER TRAINING

The plant's management system should include a means to identify the needfor refresher training on a periodic basis. The system should also makeprovisions for inputs into the training course when there are changes inprocess or equipment that can affect the safety of the operation or process.The system also needs a feedback mechanism when there are repeatedoperator errors or accidents. The training files should be documented, ex-plaining the rationale for changes to the training courses. (See Appendix 1OFfor an example of suggested frequencies for training courses related to chemi-cal process safety.)

Appendix 1OAExample of Operator Process Safety Training Program

OBJECTIVES

Improved performance that results in:

Improved operational safetyHigher level of employee competence, confidence, and self-directionImproved efficiencyImproved qualityIncreased profitability

Uniform core safety, environmental and operational requirements for all operating person-nel (i.e., what every operator must "know and be able to do").

A documented, comprehensive, and effective training program that has the confidence ofmanagement and satisfies corporate and regulatory requirements.

These achievements will be made by having:

• Uniform process information across shift.• Assurance that each employee has the level of knowledge/skill necessary to be

proactive in his or her job assignment with a minimum of supervision.—Mandatory safety training.—Critical operating parameters.—Critical procedures affecting process safety.— Special operating procedures and/or procedural steps that are required by

operational safety standards.• A training program that optimizes the time required to bring employees to the

qualification and certification levels.• Definition and documentation of what employees are expected to know and how

they are expected to respond.• Mandatory safety training that will meet requirements of refresher training.

PURPOSE

These operator standards are established to ensure the ability to improve operational safetyand performance.

SCOPE

These standards apply to all operators. These standards provide the basis for the locationsto develop specific job/unit performance standards. Each location should determine its

certification process(es) and may obtain assistance from manufacturing services, which willhave a coordinating role.

DEFINITIONS

For the purpose of these standards, the following definitions are in effect:Formal Training: Any structured program of instruction designed to present skill and/or

knowledge related to the operating function.Instructor: Any individual who presents a prescribed program of instruction, usually in

formal training session.Personnel: Any employee involved in day-to-day operation or distribution. Excludes all

exempt salary, clerical, laboratory and maintenance personnel.Practical: A performance test. (Example: Start up and shut down XYZ pump.)Shall: Denotes a requirement.Should: Denotes a recommendation.Trainer: Any individual who conducts the on-the-job training.

STANDARDS

Achievement Standards

WrittenTrainees shall achieve a minimum of 80% on all location written tests. A standard ofachievement shall be 100% on plant-identified critical operating procedures and parameters.Where government tests are administered, the minimum passing grade shall be determinedby the testing agency and shall be accepted.

Practical (hands-on performance test)All practical test questions and performance shall be documented and have a gradingsystem. Trainees shall achieve a minimum of 80% on all practical tests. A standard ofachievement shall be 100% on plant-identified critical operating procedures and parameters.Where government tests are administered, the minimum passing grade shall be determinedby the testing agency and shall be accepted.

SimulatedTests that simulate the actual activity shall be used in place of practical tests when it canbe shown that practical tersts are not feasible. Oral tests and test results from simulations,whether field conducted or classroom conducted, shall be documented.

Program Standards

All skill/knowledge programs shall have documented training objectives that detail thespecific learning and performance criteria.

All skill/knowledge programs shall have a test(s) that meets testing standards. See'Testing Standards" (p. 210).

All skill/knowledge programs shall meet or exceed required government standards.

All skill/knowledge programs shall have their contents documented and available foruse.

All skill/knowledge programs shall have published administrative procedures whichdetail trainee participation, successful completion criteria, and an evergreening process.

Locations shall have a system whereby changes in the operation and/or maintenanceprocedures shall be documented and transmitted to the appropriate personnel.

Skill/Knowledge Standards

All location operators shall meet specific job requirements established in the "Core Perform-ance Requirements."

Instructional Standards

All designated instructors of formal training programs shall successfully complete a formalinstructional seminar. Formal instructional programs should include the following criteria:job/task analysis, development of learning objectives, lesson plan development, evaluation,job instructor training (JIT), presentation skills, test construction, and documentation.

Individuals teaching one or two sessions as a part of a total program will not berequired to complete the formal instruction training, but shall have their instructionalmaterial approved by the designated instructor.

All designated trainers shall be certified on the job(s) on which they train others,and should have received JIT instruction prior to their training assignment.

Tests used for operators shall be developed and/or approved by a certified testconstructor or a recognized professional in the field of test construction or development.

Documentation Standards

Departments shall establish and maintain an auditable training records system, whichcontains as a minimum:

• The employee's name.• The name or description of any formal training undertaken by the employee.• The date and duration of any formal training.• The results of related tests and certification attained.• The expiration date of any related certificate, license, etc.• A copy of external certificates, licenses, etc. awarded.

All skill programs of study external to the plant shall include the information listed above.The documentation of successful attainment of core operator performance require-

ments as determined through a system of written and practical tests is combined withevaluation of performance on assigned work. Certification is required for the assignmentof direct accountability for specific tasks or jobs.

Phase I: Basic Operator TrainingPhase II: Job Operations Knowledge TrainingPhase III: On-the-Job Operations Skills TrainingPhase IV: Job/Unit Operating Experience Training

STRATEGY FOR IMPLEMENTING OPERATOR STANDARDS

The following steps are proposed for the implementation of the operational process safetyprogram.

1. Review proposed standards of operator process safety with location management.2. Review proposed operator standards, definitions and implementation strategy with the

manufacturing council.3. A representative group of shift and operation department heads will determine and

propose the operator job requirements.4. Manufacturing council will review the operational process safety program with its

organizations.5. Manufacturing council discusses the organizational review.6. Manufacturing services review operator standards with division, employee relations

managers, and legal staff and review results with manufacturing council.7. Manufacturing council approves operational process safety program.8. Manufacturing services to review revised proposed operator standards with directors

of manufacturing.9. Manufacturing council issues agreed on standards, definitions, and implementation

strategy to locations through the line organization.10. Plant locations devise programs to meet standards with assistance as requested from

manufacturing services.11. Manufacturing services training develops location administered audit to assure compli-

ance.12. Manufacturing council reviews implementation progress and resolves any issues.13. Locations administer audits to confirm compliance of program.14. Each department reports result of audit to plant manager.

TESTING STANDARDS

Definitions

For the purposes of these test standards the following definitions are in effect:Summative Tests: Test only terminal performance objectives. They can take the form of

written, oral or practical tests. This type of test is used to evaluate the extent to whichlearning has taken place by the trainee.

Terminal Performance Objectives: An objective that states the learning behavior a traineeis required to demonstrate on successful completion of a training course or program.This terminal performance objective is related directly to a task or tasks derived fromthe trainee's job duties.

Standards

1. As a minimum, each training program shall have a written and/or practical test,summative in nature, administered on completion of the course, which will beused as one of the criteria for objectively assessing the trainee.

2. Tests developed and used in training programs shall be designed to measureterminal performance objectives and/or verified jobs/tasks.

3. Trainees shall achieve minimum of 80% on all tests except in instances wherecritical procedures are involved, when 100% achievement shall be required.

4. Performance tests will be composed of items related directly to the requirementsof specific jobs/tasks assigned to the trainee.

5. All written and/or practical tests used to make operator certification decisionsshall be constructed or approved by a certified test constructor or a recognizedprofessional in the field of test construction or development.

6. Each location shall have clearly defined procedures for administering and docu-menting all written and/or performance tests.

BasicOperatorTraining

Operator orientation

Safety orientation

Job OperationsKnowledge Training

Process information

Operation manual

Unit safetyprocedures

SOPs

Technical concepts

On-the-JobOperations

Skills Training

Hands-on performanceof specific jobprocedures

Hands-on performanceof job and unitsafety procedures

Troubleshooting

Job/UnitOperating Experience

Training

Experience performingassigned job inmonitoredenvironment

TestWritten and Practical

Job RequirementBased on Written and

Practical Tests

PHASE I PHASE Il PHASE III PHASE IV

CORE PERFORMANCE REQUIREMENTS FOR OPERATORS

These fundamental requirements are not intended to be all inclusive to meet each location'soperator job requirements. The operator's job is very broad and these requirements repre-sent the core skills and knowledge needed. Individual locations may require additionalskills and knowledge to achieve operator certification.

I. An operator is responsible for the hands-on operation of assigned jobs and mustdemonstrate knowledge of and proficiency in the following areas for the assigned job(s):

1. Plant personnel, health, and operation safety standards2. Environmental protection policies and procedures3. Standard operating procedures (SOPs)4. Critical operating parameters (COPs)5. Emergency operating procedures (EOPs)6. Safety equipment7. Basic process technology8. Process flows and equipment9. Process control systems and computer systems

IL An operator, as a minimum, shall be able to perform the following for his or herassigned job(s):

1. Make process and equipment adjustments to safely control unit efficiency, produc-tion, and product quality within prescribed limits.

2. Inspect and observe equipment and process operation for abnormalities.3. Troubleshoot equipment and process operation when abnormalities are recognized

and take appropriate corrective action.4. Immediately and correctly respond to any COP reaching its "never exceed" limit.5. Recognize, analyze, and correctly respond to emergency situations.6. Make minor repairs and routine maintenance given the necessary authorization.7. Identify items in need of maintenance and initiate requests for action.8. Prepare equipment for maintenance.9. Provide timely, complete, and accurate written and oral communication.

Appendix 1OBExample of Maintenance Training Program forProcess Safety

OBJECTIVES OF MAINTENANCE OF PROCESS SAFETYTRAINING PROGRAM

• To provide a safety net around the performance of critical work.• To establish location-specific safety, environmental, and operational requirements

for the performance of critical work; that is, work that has the potential for directlyimpacting the operational safety of the unit/location and for which no other safetynet exists.

• To establish an effective and documented training program that has the confidenceof management and satisfies corporate and regulatory requirements.

PURPOSE

These maintenance standards establish criteria to promote excellence in the performanceof maintenance functional activities which could potentially affect unit-specific operationaland/or maintenance safety and which have no safety net. The unit operational safetystandards shall be utilized as the first source to identify maintenance tasks, if another safetynet cannot be provided.

SCOPE

These standards apply to all maintenance personnel and provide the basis from whichthe Maintenance Department shall develop unit-specific skill/craft performance standards.Assistance may be obtained from Manufacturing Services personnel, who will have acoordinating role. (Action plans associated with implementation of the maintenance stan-dards are contained in Attachment 1).

DEFINITIONS

The following definitions apply to these standards:Critical equipment: Systems, components, or equipment whose total or partial malfunction

could lead to a hazardous event and for which no safety net exists.Critical maintenance work: Performed on critical equipment, tasks where a deficiency in

task performance could result in a major hazard event; that is, deficient performancecould potentially impact unit-specific operational safety.

Formal training: Any structured program or course of instruction designed to develop skills,and/or knowledge related to a specific task.

Instructor: Any individual who presents a prescribed program of instruction, usually in aclassroom, lab, or job simulation.

Maintenance personnel: Employees who perform critical maintenance work.May: Denotes an option.Practical: A hands-on performance test. (Example: welding certification tests)Safety net: A design, procedural, or human action that assures that critical control estab-

lished by the operational safety standards is met.Shall: Denotes a requirement.Should: Denotes a recommendation.Standards: Documentation of attainment of job performance which meets specific mainten-

ance critical work standards required to perform tasks without supervision.Trainer: Any individual who conducts formal on-the-job training.Unit specific: Refers not only to a process unit, but also to any operational area, that is,

utilities, distribution, laboratory, or maintenance.

STANDARDS

Maintenance Standards

Unit-specific maintenance critical work tasks and knowledge required for certification shallbe identified, documented, and then developed through a system of training and testingthat typically includes the following:

• Unit critical work training• Unit critical work on-the-job training• Experience performing assigned critical maintenance work.

Lists of critical tasks and knowledge shall be reviewed periodically and revised asnecessary. Attachment 2 presents a sample listing of critical work tasks.

Verification of critical task training (Attachment 2) is required in advance of perform-ance critical work without supervision. Locations shall write a variance procedure to meetunusual situations where circumstances dictate variances in the use of certified personnel.

Achievement Standards

WrittenThe standard of achievement shall be 100% on location identified maintenance tasks andknowledge associated with critical work. Where goverment tests are administered, theminimum passing grade shall be determined by the testing agency.

Practical (Hands-on Performance Test)Skill performance tests shall be documented and have a pass/fail grading system. If a writtenor oral test is administered as part of a skill performance test, the standard of achievementshall be the same as for written tests.

SimulationTests which simulate the actual activity shall be used in place of skill performance testswhen it can be shown that skill performance tests are not physically possible or practical.Oral tests shall document questions and answers.

Test OutWith the approval of location management, maintenance personnel may forego training onspecific topics if they meet the certification knowledge and skill requirements by passingapproved tests prior to the scheduled training.

Maintenance Critical Skill Program Standards

Maintenance critical skill/knowledge programs shall have established training objectives,successful completion criteria, and administrative procedures which document trainee par-ticipation and performance. Programs also provide a continuing training and recertificationprogram to ensure employee skills and knowledge are maintained.

Maintenance critical skill programs shall have tests that meet C&P testing standards.(See Attachment 4 for testing standards).

ATTACHMENT 1. MAINTENANCE STANDARDS ACTION PLANS

1. DevelopA. List of representative plant crafts.B. List of crafts to be considered for certification.

2. Develop criteria for maintenance proceduresA. Define term and uses of maintenance procedures (give examples)B. Define —unit maintenance proceduresC. Define—internal maintenance procedures

3. Rework certification standards and issue to maintenance managers for review4. Revise Items 2 and 3 as needed5. Issue revised certification standards for review by maintenance managers6. Issue for final review of the maintenance certification standards at maintenance

managers meeting7. Manufacturing Services reviews certification standards with employee relations

(ER) managers and legal staff8. Issue final draft of standards to maintenance managers which includes cost esti-

mate to implement program9. Issue final draft of standards to plant management for review

10. Review certification standards for approval with manufacturing council11. Manufacturing council issues agreed on certification standards through the line

organization12. Manufacturing council reviews progress and resolves any issues13. Plant management administers evaluation to confirm compliance of the mainten-

ance program

ATTACHMENT 2. EXAMPLES-POTENTIAL CRITICAL WORKMAINTENANCE TASKS

Test and Inspection, Preventive Maintenance of Critical Equipment

• Process lines• Vessels• Pressure relief devices, that is, safety valves, rupture disks, vacuum breakers• Vents• Turbine overspeed trips

Functional Checks of Critical Instruments

• Alarms• ESOs• On-stream analyzers• Leak detection equipment

UnitCritical Work

Training

Procedures

Tasks/equipment

Unit processes

Unit Critical WorkOn-the-Job

Training

Hands-on performanceof specific maintenancetasks or skills

Hands-on performanceof maintenance safetyprocedures

Experience PerformingAssigned Critical

Maintenance Work

Experience performingassigned criticalwork in opratingunits

Experience usingspecific safetyprocedures andprecautions basedon unit process,equipment, andprocess material

Unit-SpecificMaintenanceTask Certified

Based on writtenand practicaltests

Special MOC Requirements

• Gaskets, sealants, lubricants, oils, etc.• Expansion joints• Special cleaning, for example, cleaning for oxygen service• Vessels, process lines, fittings, etc.

Special Equipment Requirements

• Throttle bushings on pumps• Leak limiting devices on pumps• Orifices• Thermocouples• Power dip protection• Maintenance specifications

Notes

1. If identified as critical controls in Operational Safety Standards2. If no other safety net exists

ATTACHMENT 3A. SPECIFIC EX AMPLES -POTENTI ALCRITICAL WORK TASKS METHYL GLYCOL ETHERS UNIT

Test and Inspection, Preventive Maintenance

• Visual inspection of insulation on oxideliner every 5 years

• Thickness check of oxide and methanolliners every 5 years

• Pressure test of reactor tube bundle every5 years

• Internal and external inspection ofcolumns every 5 years

• Preventive maintenance of all unit safetyvalves

Functional Checks of Critical Instruments

• Annual check of critical alarms• Annual check of critical emergency

shutdown (ESD) systems• Calibration of catalyst flow meters

Special MOC Requirements

• Inspection of oxide replacement valves for

TASK

CERTIFICATION

X

X

XX

X

PROCEDURAL

VERIFICATION

TASK CERTIFICATION

X

X

X

X

proper gaskets and packing prior toinstallation

• Assure that no asbestos insulation is used Xin the unit

Special Equipment Requirements

• TRF pump must be installed with high Xtemperature trip and low recycle flow trap

ATTACHMENT 4. MAINTENANCE TESTING STANDARDS

1. As a minimum, each training program shall have a written and practical test whichis summative in nature and administered on completion of the course. The testresults will be used as one of the criteria for asessing the trainee.

2. Tests developed and used in training programs shall be designed to measureinstructional objectives and/or verified jobs/tasks.

3. Trainees shall achieve 100% on all written tests addressing critical work relatedknowledge.

4. Tests will be composed of items related directly to the critical work requirementsof specific jobs/tasks assigned to the trainee.

5. Written and/or practical tests used to make certification decisions shall be con-structed or approved by a C&P certified test constructor or a recognized profes-sional in the field of test construction or development.

6. Each location shall have clearly defined procedures for administering and docu-menting written and/or performance tests.

Definitions

For the purposes of these test standards the following definitions apply:Enabling objective: An objective in a set of objectives that supports the attainment of a

terminal objective. Each enabling objective represents a significant step in attaining theterminal objective.

Summative tests: Tests that focus on overall achievement of trainees in a course/program,that is, they test terminal and enabling instructional objectives. They can take the formof written, oral, or practical tests.

Terminal performance, objective: An objective that states the learning behavior a traineeis required to demonstrate on successful completion of a training course or program. Aterminal objective is related directly to a task or tasks derived from the trainee's jobduties.

Maintenance Critical Skill Program Standards

Maintenance critical skill programs shall meet or exceed existing government standards.Maintenance critical skill programs shall have their contents documented and avail-

able for use.The Maintenance Department shall have a system whereby changes that could affect

maintenance critical work shall be documented and transmitted to personnel affected by

the changes (e.g., design changes and procedure changes). Training personnel should reviewthese changes to determine if revisions are required to the training program.

Instructional Standards

Designated instructors of formal training programs shall be approved by their locationmanagement on their successful completion of a formal instructional techniques seminar.Formal instructional programs should include the following content: job/task analysis,development of learning objectives, lesson plan development, evaluation, job instructortraining (JIT), presentation skills, test construction, and documentation.

This training can be obtained through the internal certification program sponsoredby Manufacturing Services or through an external organization.

Tests used for maintenance certification shall be developed and/or approved by acertified test constructor or a recognized professional in the field of test construction ordevelopment.

Trainers shall be certified in the unit-specific tasks in which they train others andshould have received JIT instruction prior to their training assignment.

Documentation

The Maintenance Department shall establish and maintain an auditable training recordssystem on critical tasks which contains, as a minimum:

• The employee's name and social security number.• The name and description of any formal training undertaken by the employee.• The name of the instructor and the date and duration of any formal training.• The results of related tests and certification attained.• The issue and expiration dates of any related certificate, license, etc.• A copy of external certificates and/or licenses.

All skill programs of study which are external to C & P shall be similarly documented.

Contractor Requirements

Contract personnel performing critical work must meet the maintenance training standards.If contract personnel do not meet these standards, critical work must be inspected andendorsed by certified plant personnel to assure it meets the plants' standards.

Vendor personnel performing critical work on equipment they manufactured havetotal responsibility for that work.

Appendix 1OCExample of Operations Technical Staff Training Program

CONTENTS

Purpose Statement

Program Summary

Program Mandatory Standards

Program Implementation Plans

Program Accountabilities

Mandatory TrainingSafety, Health, and Environmental ProceduresUnit-Specific Operational Safety StandardsUnit-Specific TechnologyOperational Safety WorkshopOperations Environmental Workshop

Advanced Technical TrainingInstrumentation and AnalyzersMechanical TechnologyPlant Accounting SystemsProcess Computer Control and OptimizationProcess EconomicsProject/Program ManagementStatistical Process Control I and IIUnit Operations for Non-Chemical Engineers

Definitions

PURPOSE STATEMENT

The purpose of this program is to provide the basis for this plant to develop specific job/unitoperations training program for technical staff personnel.

The implementation of this program will result in:

• Technical training programs that are consistent in scope and development through-out the plant and that have the support of management at all levels.

• Accelerated development of new and inexperienced technical personnel.• Improved operational and safety performance by increasing the level of individual

employee competence and confidence.• Improved definition of host and tenant training responsibilities.• Improved ability to identify and meet the technical skills required to achieve

production, operational safety and environmental protection goals.

PROGRAM SUMMARY

There are three phases of the model Operations Technical Staff Training Program. Theresponsibilities and criteria for the mandatory and advanced technical phases are developedin this document. The developmental training consists of training that is already availableand can be provided by human resources staff.

I. Mandatory Training

Safety and health and environmental procedures*Unit-specific operational safety standards*Unit-specific safety workshopOperational safety workshopOperations environmental workshop

IL Advanced Technical Training

Instrumentation and analyzersMechanical technologyPlant accounting systemsProcess computer control and optimizationProcess economicsProject/program managementStatistical process control I and IIUnit operations for non-chemical engineers

III. Developmental Training

Cost improvementCreativity and innovationInterpersonal skillsManagerial economicsOral communicationPerformance appraisalsPersonal computer applicationProblem solving and decision making analysisProductivity managementSpecialized technology training (depends on specific unit assignment)Stress managementWritten communications

*Contains core training topics.

PROGRAM MANDATORY STANDARDS*

1. A documented training plan for each operations department technical staff memberwhich must identify the mandatory training, advanced technical training, anddevelopmental training for the individual that has been taken or is planned.

2. Core training must include testing to confirm that training objectives have beenmet.

3. The Operations Technical Staff Training Program must be implemented in accord-ance with the Operational Safety Program.

4. Each location must be responsible for determining the mandatory training require-ments for experienced technical staff members and retraining requirements fortransferred technical staff members.

5. Documentation of the technical staff member's participation in the OperationsTechnical Staff Training Program must be the responsibility of the individual'slocation.

PROGRAM IMPLEMENTATION PLANS

The following implementation details are subject to change. They are not considered as amandatory part of this program.

1. The Technical Staff Training Steering Committee will continue to oversee thedevelopment and maintenance of the program.

2. Manufacturing services training will be responsible for coordinating the develop-ment and instruction of the advanced training subjects based on locations' priorityand request.

3. Outside consultants will be utilized for program development and instructionwhere needed to minimize additional workload for plant personnel. Existing pro-grams will be reviewed and, if possible, used in the development of the advancedtechnical training program.

4. Courses for development training are available from outside sources or within thecompany.

PROGRAM ACCOUNTABILITIES

The matrix shown on the facing page indicates categories of mandatory and advancedtraining in the Operations Technical Staff Training Program and the program trainingdevelopment accountabilities.

*Boldface words are defined on page 231.

MANDATORY TRAINING

Safety, Health, and Environmental Procedures

PurposeThe purpose of this training is to provide a knowledge of critical safety, health, andenvironmental procedures that are designated mandatory for operations technical day staffpersonnel. Each location/unit must identify its mandatory and core training topics.

ObjectivesOn completion of this training, the trainee will be able to demonstrate a working knowledgeof the training topics that have been indentified as mandatory by the location. The followingtopics may be considered as an example:

Life critical proceduresHazard communicationsEmergency response proceduresIndustrial hygiene issuesFacility change and pre-start-up reviewsAccident/incident investigation procedures

I. Mandatory Training

A. Safety, Health, and EnvironmentalProcedures

B. Unit-Specific Operational SafetyStandard

C. Unit-Specific Technology (Core)Unit-Specific Technology (Not Core)

D. Operational Safety WorkshopE. Operations Environmental Workshop

II. Advanced Training

A. Statistical Process Control I and IlB. All Other Advanced Training

TRAINING

H

H

HHHH

HH

DEVELOPMENT

H

H

TTMSMS

QDMS

SCHED& COND

H

H

HTMSMS

QDMS

TRAINING: Accountability to see target employees are trained.DEVELOPMENT: Accountability for training development.SCHED & COND: Accountability for scheduling and conducting training activities.

H = HostT = Tenant

MS = Manufacturing ServicesQD = Quality Directors

Unit-Specific Operational Safety Standards

PurposeThe purpose of this mandatory topic is to provide identification of major process hazards andrisk management systems associated with unit operations, including activities encompassinghandling of raw materials, processing, storage, and product handling in all operating modes.This is a core training requirement. Each location/unit must assure that the technical staffhas received training on their unit-specific operational safety standards.

ObjectivesOn completion of this course, the trainee will be able to demonstrate a working knowledgeof:

• Major Process Hazards• Possible Causes and Effects• Standards for Risk Mitigation

— Administrative Controls—Critical Operating Parameter Limits— Critical Controls— Operating Restrictions— Special Materials Specifications— Special Procedures— Special Test and Inspection Requirements— Critical Equipment, including emission control devices which must be in service— Special Equipment Design Standards

• References

Unit-Specific Technology

PurposeThe purpose of this course is to provide an introduction to the unit-specific knowledge andskills necessary to perform the assignment of a technical staff employee's job safely.

ObjectivesOn completion of this course, the trainee will be able to:

• Explain the processes utilized in the participant's assigned area that converts rawmaterials physically and/or chemically into desirable products.

• Draw from memory a diagram of major process flows and equipment including keyprocess control loops and operating conditions.

• Explain the operation of ESD systems.• Explain, audit and update SOPs, COPs, and EOPs.• List technical resources available for consultation on technical issues.• On nonmandatory basis, provide detailed technical background to optimize, trou-

bleshoot, lead process revisions and train other personnel.

The above objectives shall be accomplished in each unit by considering and incorporatingas deemed appropriate the content criteria described below.

Content Criteria(Core topics are identified by asterisks.)

I. Technology Basis* Chemistry

* Reactions* Potential uncontrolled/runaway reactions* Physical properties* Hazardous properties

* Major unit operations* Safe operating envelope* Special technologies or equipment which could impact HS&EA

II. Unit Design Basis* Detailed process and material flow diagram* Operating conditions and limits (i.e., temperature, pressure flow, composition, physi-

cal state, etc.)* Process control* Safety systems (ESS, safety valve, etc.)

Materials of construction* Special HS&EP considerations

III. Process Material and ProductsWorking knowledge of specifications

Raw materialsOther process materialsProducts

* Handling and storage considerations

IV. Process-Specific HS&EP Issues* Health effects, acute and chronic* Waste and emission minimization* Episodic incidents

* TypesReaction runawaysFires/explosionsLethal releases

* Potential impactUnitPlantCommunity

* Reportable quantities* Review of previous significant events

(Industrial and subject process/unit)

V. Operating Procedures and References*SOPs*EOPsReferences which trainee must be familiar with

DOT or other R&D reports

Safety considerations reportOSHSPRSFMEATechnical resources for consultation

VI. Optional ContentCommercial objectives for facilityOperations strategy (how to meet commercial objective)Major equipment design basisLayout design considerationsAnalytical methods

Operational Safety Workshop

PurposeThe purpose of this workshop is to provide specific training to manufacturing personnel ontechnical subjects and resources. The program is focused on hazards identification and riskassessment and control.

ObjectivesOn completion of this workshop, the trainee will be able to:

• Describe the Operational Safety Program in terms of content, historical basis andoverall objectives.

• Describe the techniques used in hazard/risk assessment.• Access operational safety references and resources for future information. Explain

the application of the TMS system.• Describe the design principles for inherent design safety.• Describe the flammability hazards control associated with the potential of static

electricity, flammable mixtures inside equipment, and from vapor and liquid spills.• Describe and interpret the application of operational safety standards to mitigate

major process risks.• Explain the concepts of reaction control associated with contamination and com-

patibility of chemicals and mixtures and the techniques in controlling risks associ-ated with uncontrolled reaction.

• Explain the valve and piping specification and the way in which design providesfor operational safety.

• Describe corrosion mechanisms and measurement techniques.• Describe corrosion prevention and control techniques.• Explain the basis for preventive maintenance and test and inspection programs to

assure integrity of process equipment.• Describe and identify types of pressure relief devices, applications and correct

installation, and preventative maintenance for each type.• Describe the concept and application of critical instruments and alarms to risk

mitigation.• Describe the role of the computer, including distributive control systems, in process

control and risk mitigation.• Describe electrical safety as it affects operational safety.

Operations Environmental Workshop

PurposeThe purpose of this course will be to provide all operations technical day staff personnelwith information about the environmental laws and regulations that pertain to their work.

ObjectivesOn completion of this course, the trainee will be able to:

• Provide on a broad overview basis the regulatory environmental requirementswithin his or her area, including:—The Resource Conservation and Recovery Act (RCRA) requirements.—The Clean Water Act requirements (includes NPDES, SPCC requirements).—The Clean Air Act requirements (includes asbestos requirements).—The Toxic Substance Control Act (TSCA) requirements (includes PCB require-

ments).—The Superfund/SARA requirements.— All permits specific to the area.—Groundwater protection requirements.

• Provide on a broad overview basis the basic company environmental requirementswithin his or her area, including:— Waste disposal procedural requirements.— Spill/release reporting requirements.—Waste minimization requirements.— Environmental emissions inventory (both continuous and episodic potential) for

all media.— All applicable procedures (corporate through location).

ADVANCED TECHNICAL TRAINING

Instrumentation and Analyzers

PurposeThe purpose of this course is to provide the trainee with an overview of the subject matter,but with sufficient detail that the trainee will be able to assure the process safety ofoperations.

ObjectivesOn the completion of this course, the trainee will be able to:

• Describe the function and operation of instrumentation used to measure, indicate,record and control process variables such as:—Temperature—Pressure—Flow

— Differential pressure-Level—Control valve specifications and selection of individual valves

• Explain the elementary theory of process control of processes by describing lagtime, cycling, alternate ways to control a variable, failure modes and ways to tunea control loop.

• Read and explain a loop sketch and identify symbols used to designate controlelements on P&CDs.

• Describe on-line analyzers and explain the advantages and disadvantages of differ-ent types of equipment which impact accuracy, reliability, and onstream time.

• List the technical resources who are available in central engineering to solve com-plicated problems.

Mechanical Technology

PurposeThe purpose of this course is to provide a knowledge of mechanical equipment design andoperation and of materials of construction to enable the technical staff to better understandequipment operation, assist in troubleshooting and be better able to make unit modificationsinvolving equipment.

ObjectivesOn completion of this course, the trainee will be able to:

• Describe the design and service characteristics of pumps, mechanical seals, coup-lings, turbines and drivers, compressors, motors, process piping, agitators, refriger-ation system, vacuum devices, and safety devices.

• Troubleshoot mechanical equipment and effectively communicate with mainten-ance and other technical specialists regarding mechanical problem definition andresolution in his or her assigned area.

• Effectively communicate in the areas of metallurgy and corrosion protection withmaintenance and other technical specialists regarding problem definition and reso-lution in his or her assigned area.

• Read detailed equipment drawings; use valve and piping specification manual.• Review mechanical design of major chemical processing equipment, i.e., heat

exchangers, columns and pressure vessels.

Plant Accounting Systems

PurposeThe purpose of this course is to present the terminology, sources, uses, and value ofavailable plant accounting systems.

ObjectivesOn completion of this course, the trainee will be able to:

• Describe Period Cost— Difference between and source of prime costs, shared costs, and fixed costs—Type of detail reports available and their value

• Describe Variable Cost—Meaning of pers, standard unit cost, transfer price, variance— How numbers on cost sheets are derived— How to identify sources of variances

• Describe Capital— Definition of minor property vs. working budget vs. major capital— Methods of submitting major capital projects—Type of reports available and their value

• Explain Plant Budgeting Procedure—Techniques used to prepare an annual department budget—Definition of capital vs. expense.

Process Computer Control and Optimization

PurposeThe purpose of this course is to provide an understanding of the application of technologythat exists for direct computer control and optimization for manufacturing processes.

ObjectivesOn completion of this course, the trainee will be able to:

• Apply process computer control systems to optimize participant's assigned processfor volume, profit, and reduced operating costs.

• Describe the computer control applications existing in participant's area, and iden-tify expertise and consultants available as resources.

• Determine the potential applications for systems in participant's assigned area toidentify cost and environmental or operational safety benefits.

• Describe available process computer control technology.

Process Economics

PurposeThe purpose of this course is to present the techniques and methods to calculate andevaluate efficiency of a process unit.

ObjectivesOn completion of this course, the trainee will be able to:

• Calculate the cost of material efficiency or energy usage changes.• Explain how to determine the profitability of operating a unit (true cost of down-

time).• Explain how to analyze and compare the costs of reduced rate operation versus

full rate block operation.

• Describe (list) factors to be considered for estimating the cost of maintenancerepairs.

• Prepare project justification economics (excluding DCF analysis).

Project/Program Management

PurposeThe purpose of this course is to present to the trainee the techniques and methods ofproject funding and management.

ObjectivesOn completion of this course, the trainee will be able to:

• Explain the method of obtaining funding and approval for projects.• Describe the Project Management System that identifies design responsibilities

between the plant and engineering and the interface with the business managers.• Define the meaning of minor property, expense, capital, and major capital monies

and give actual examples of each.• Describe techniques to facilitate project management.

Statistical Process Control I and II

PurposeThe purpose of these courses is to present the working techniques and methods of statisticalprocess control and its impact on the improvement of product quality.

ObjectivesOn the completion of Section I, the trainee will be able to:

• Describe what statistical process control can and cannot do to improve productquality and yield, and to reduce product cost.

• Describe data organization and presentation techniques to (1) visualize processes,(2) collect and organize data effectively, and (3) present data using statisticalsummary and graphical techniques.

• Effectively apply the following statistical process control techniques in improvinghis or her process:—Shewhart Charts—Process Capability-EWMA Charts—Multivariant Charts—Cusum Charts

On the completion of Section II, the trainee will be able to:

• Use statistical methods knowledge to analyze results of:—Process definition and comparison studies—Variance analysis studies—Regression and correlation analysis

—Design experiments—Time series analysis and dynamic process modeling

Unit Operations for Non-Chemical Engineers

PurposeThe purpose of this course is to present introductory information about all chemical unitoperations.

ObjectivesOn completion of this course, the trainee will be able to:

• Explain introductory information about all chemical unit operations and will beable to identify and describe all operations in the unit(s) to which he or she isassigned or indirectly supporting.

• Communicate with engineering and R&D specialists using chemical engineeringterms regarding problem definition and resolution in his or her assigned area.

• Perform simple unit operations engineering calculations to evaluate and resolveless complex problems and projects in his or assigned area, such as:—material balancing—energy balancing—pressure drop calculations—pipeline sizing—pump sizing

DEFINITIONS

Core: Core training is that part of mandatory training related to the individual's area thatis required prior to authorization to direct the activities of others.

Mandatory: Mandatory training is that training required of technical staff employees within24 months of an assignment to an operations department.

Operations: An operation is defined by the Operational Safety Program as "any activitywhich includes one or more of the following: manufacturing, distribution, storage, mixingand blending, waste treatment, pilot plant, pipeline and energy systems operations."

Appendix 1ODExample of Maintenance Training Implementation(Estimated Cost/Person)

ASSUMPTIONS

1. Total cost represents an average of two plants' estimates (Plant A/$3,000 per personand Plant B/$5,540 per person).

2. Costs are based on $20 per hour (not on sold service rates).3. Costs do not include contractor costs.4. Material costs will be aproximately 10% of the manhour costs.5. Plant A estimates that approximately 10% of the persons taking the tests will fail;

therefore, approximately 90% of the incumbents will not require training. Plant Bestimates that 85% of the persons taking the test will fail.

6. One certified instructor will be sufficient for each job classification.7. Each certified instructor will attend two outside technical training courses.8. Costs are based on a 1:6 training/development ratio, i.e., one hour of presentation will

require approximately six hours of development.9. Tests will average two hours per test and approximately twenty tests will be required.* Locations may choose to develop in parallel.

Maim.Tech. &Crafts-person

PL.MGR.ISSUECHARGETO M.S.TO DEVEL.STDS.

Complete1991

M.S.COOR.STD.DEVELOP& PLANT,LEGALDERMREVIEWS

2Q92

MAlNT.DEPT.REVIEWSTD.& ISSUEFORIMPLEMENT.

3Q92

MAlNT.DEPT.DEVELOPPLAN TOIMPLEMENTSTDS.

1Q93

MFG. SVCSEVALUATIONOF STDS.IMPLEMENT.

2Q93

IMPLEMENTSTDS. FOREXISTINGPERSONNEL*

3Q93

DEVELOPTRNG.PROGRAMFOR NEWHIRES*

4Q93

TOTALEST. COSTFORIMPLEMENTPROGRAM(000)

$8,000

Appendix 1OEExample of Instructional Standards

Designated instructors of formal training programs shall successfully complete a formalinstructional seminar. Formal instructional programs should include the following content:job/task analysis, development of learning objectives, lesson plan development, evaluation,job instructor training (JIT), presentation skills, test construction, and documentation.

Individuals teaching one of two sessions as part of a total program will not be requiredto complete the formal instruction training but shall have their instructional material ap-proved by a designated instructor.

Trainers shall be certified on the tasks in which they train others and should havereceived JIT instruction prior to their training assignment.

Tests shall be developed and/or approved by a recognized professional in the fieldof test construction or development.

Appendix 1OFExample of Refresher Training Course Frequencies

Training Frequency0 = Initial Appreciation1 = Annually2 = Every Two Years3 = Every Three Years

Plant Safety Organization

Basic Fire Safety

Managerial Responsibilities for Safety

Risk Management

Emergency Management

Hazard Identification

Mathematics

Material lncompatability

Accident Reporting Procedures

Safe Handling of Toxic Materials

Administrative Control and ApprovalProcedures for Process Safety

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