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Occupational Title: Chemical/Refining Process Technician |
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Critical Work Function |
Occupational Skills, Knowledge and Conditions |
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Key Activities |
Performance Criteria |
Occupational Skills and Knowledge |
Conditions |
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Those duties or task clusters that are necessary to perform each critical work function. |
Specific demonstrable performance and standards that indicate when the key activity has been performed successfully. |
Those skills and knowledge that are specific to the occupation, such as technical processes or procedures common across the occupation that are critical to the related key activity. |
Tools, resources and equipment necessary to carry out key activities and their related performance criteria. |
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KA8.1
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Diagnose Malfunction or Abnormality |
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Process Variables - Knowledge of effects
and relationships of process variables such as pressure, composition,
temperature, level, and flow. Operating Parameters - Knowledge of
normal operating procedures and design limits, and the differences between
them. System Components - Knowledge of system
components and their functions (e.g., stationary equipment, rotating
equipment, instrumentation and controls). SHE (Safety, Health, & Environment)
-Understand incidents, hazards (e.g., electrical, physical, chemical,
biological, environmental), risks (e.g., releases, equipment failures,
chemical incompatibility, and other exposures), audits, investigations, and
unsafe work practices, and awareness of critical
federal, state, and local regulations (e.g., OSHA, EPA, USCG, and DOT; read
and interpret MSDS sheets) in order to help ensure compliance with the
regulations. Procedures - Understand and follow
established procedures to operate safely, efficiently and in an
environmentally sound manner (e.g., emergency, startup, shutdown, SOP, LOTO,
emissions violations, and other OSHA regulated procedures). Maintain Quality - Optimize process
systems by acquiring data and making adjustments. Instrumentation and Control Systems
-Knowledge of measurement, controls (e.g., indicators, recorders, and
gauges), instrumentation (e.g., manual, automatic, cascade, and ratio) and
Distributive Control Systems (DCS). Troubleshooting -Ability to recognize a
problem, collect and analyze information, define root cause, and take an
appropriate plan of action. Process Symbols - Understand symbols used
in process diagrams. Use Process Drawings - Interpret and
sketch process diagrams (e.g., block/flow, process flow, and P&ID) in
order to trace and learn systems, and to aid communication. Boilers - Understanding of boiler
fundamentals (e.g., boiling point, latent heat, superheat, radiant heat,
desuperheating, chemical addition, H2O quality, thermal shock) and how the
boiler system works (e.g., heat recovery). Steam Generation/Distribution
-Understanding of steam generation fundamentals (e.g., BFW– boiler feed
water- quality; superheaters; dry vs. wet steam; excess O2 control; excess O2 fuel
air control; pressure-temperature relationship; boiler level; shrink and swell; three element control) and the
purpose and types of steam generation systems (e.g., Drafts – natural,
forced, balanced, induced fire-tubed, water
tubed, tube and shell; Source of Heat – gas, oil, coal, electrical, dual
fuel, and waste heat) and the understanding of
steam distribution (e.g., headers, pressure let down, steam traps, and condensate recovery). Instrument Air - Understanding of
instrument air fundamentals (e.g., compression, dewpoint, filtration, system
pressure) and instrument air systems (e.g., dryers,
filters, cycles, compressors, desiccant filters, switching, receivers, KO
pots, back-ups – N2 utility air). Utility Air - Understanding of utility
air fundamentals (e.g., higher pressure and moisture content than instrument
air, compression, uses-pneumatics,
atomization, waste treatment) and utility air systems (e.g., filters,
compressors, headers, manifolds, and back-ups). Material Sampling - Knowledge of sampling
techniques and of proper labeling procedures for samples collected. Quality Assurance - Interpret and verify
quality (e.g., certificate of analysis) and quantity when receiving
materials. Hazard Labeling - Knowledge of standard
labeling systems (e.g., NFPA for equipment). Equipment Monitoring - Conduct physical
inspections of equipment (e.g., tanks, pipes, drums, pumps, vents, and safety
equipment). Inventory Control - Knowledge of
inventory control fundamentals and its impact. PPE - Knowledge of personal protective
equipment and their appropriate use. Safety Equipment Operations Knowledge of
operating safety equipment. Boiler Feed Water - Understanding of
boiler feed water fundamentals (e.g., pressures, phase change/flash point,
uses, sources, makeups, chemical treatment, hydrology) and boiler feed water
systems (e.g., dearators, softeners, accumulators, demins, blow downs,
condensate return). Steam Condensate - Understanding of
condensate fundamentals (e.g., condensate purity, system pressure, uses,
sources) and condensate systems (e.g., flash tanks, drain pots, desuper
heater, steam traps, analyzers, let down stations). Natural Gas - Understanding of natural
gas fundamentals (e.g., properties & chemistry of natural gas, uses -
blanketing, fuel, processes, sources - local utilities, pipelines) and
natural gas systems (e.g., pilot gas, compressors, regulators, KO pots,
emergency shut downs). Fuels - Understanding of fuel
fundamentals—liquids, solids, and gases (e.g., sources, types, fluctuations
in make-up, BTU) and fuel system components (e.g., regulators, knockouts,
mixing areas, scrubbers, back-up systems, vaporizers, atomizers, conveyors). Nitrogen - Understanding of nitrogen
fundamentals (e.g., inert, properties, hazards, uses, sources) and nitrogen
systems (e.g., regulators, knock-out pots, generators-varies by site,
compressors, analyzers, O2 content). Water Systems - Understanding of
fundamentals of water systems (e.g., potable, process, utility, fire,
service, storm, waste) and water system components (e.g., filtration,
clarification, tanks, aeration, reverse osmosis, demineralization, and
deionization). |
Drums Hoses Compressors Extruders Flares Boilers Cryogenic unit Economizer Switch gears Skimmers Steam traps Gloves Respirator Acid suit Ear muffs SCBA (Self-Contained Breathing Apparatus) Face shield Motor control centers Reverse osmosis unit Safety goggles/glasses Drum dolly Pumps (centrifugal, vacuum, positive
displacement) Drivers (such as electrical motors, steam
turbines, gas turbines, air drivers) Piping Scrubbers Valves Filters Demisters Condenser Generators Transformers Aerators Clarifiers Fork lift Hand truck Slicker suit Hard hat Eyewash fountain FRCs (Flame Retardant Clothing) Thermal suit Furnaces/fired heaters Fire extinguisher Metatarsal guard Control valve (regulator) Instrumentation (analyzers, gauges,
control loops, temperature sensing devices) Tools (such as sample thief, strapping
tape, pipe wrench, channel locks, valve wrenches) Tubing Tanks Resins Cooling towers Dryers Eductors Meters Incinerator Basins pH meters Superheaters Safety boots Ear plugs Safety shower First aid kit Fire monitors Tower (tray, packed) API separators/traps Microfiltration equipment Desuperheaters Heat exchangers (coolers, reboilers,
fans) Heat recovery steam generator (waste heat
boiler) Reactors (batch stirred tank or
continuous stirred tank, fixed bed catalyst or fluidized be catalyst) Fittings Safety harness Personal lift Computers UPS (uninterruptible power source) |
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KA8.2 |
Remedy Equipment/Process Malfunction |
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Process Variables - Knowledge of effects
and relationships of process variables such as pressure, composition,
temperature, level, and flow. Operating Parameters - Knowledge of
normal operating procedures and design limits, and the differences between
them. System Components - Knowledge of system
components and their functions (e.g., stationary equipment, rotating
equipment, instrumentation and controls). SHE (Safety, Health, & Environment)
-Understand incidents, hazards (e.g., electrical, physical, chemical,
biological, environmental), risks (e.g., releases, equipment failures,
chemical incompatibility, and other exposures), audits, investigations, and
unsafe work practices, and awareness of critical
federal, state, and local regulations (e.g., OSHA, EPA, USCG, and DOT; read
and interpret MSDS sheets) in order to help ensure compliance with the
regulations. Procedures - Understand and follow
established procedures to operate safely, efficiently and in an
environmentally sound manner (e.g., emergency, startup, shutdown, SOP, LOTO,
emissions violations, and other OSHA regulated procedures). Maintain Quality - Optimize process
systems by acquiring data and making adjustments. Instrumentation and Control Systems
-Knowledge of measurement, controls (e.g., indicators, recorders, and
gauges), instrumentation (e.g., manual, automatic, cascade, and ratio) and
Distributive Control Systems (DCS). Troubleshooting -Ability to recognize a
problem, collect and analyze information, define root cause, and take an
appropriate plan of action. Process Symbols - Understand symbols used
in process diagrams. Use Process Drawings - Interpret and
sketch process diagrams (e.g., block/flow, process flow, and P&ID) in
order to trace and learn systems, and to aid communication. Boilers - Understanding of boiler
fundamentals (e.g., boiling point, latent heat, superheat, radiant heat,
desuperheating, chemical addition, H2O quality, thermal shock) and how the
boiler system works (e.g., heat recovery). Steam Generation/Distribution
-Understanding of steam generation fundamentals (e.g., BFW– boiler feed
water- quality; superheaters; dry vs. wet steam; excess O2 control; excess O2 fuel
air control; pressure-temperature relationship; boiler level; shrink and swell; three element control) and the
purpose and types of steam generation systems (e.g., Drafts – natural,
forced, balanced, induced fire-tubed, water
tubed, tube and shell; Source of Heat – gas, oil, coal, electrical, dual
fuel, and waste heat) and the understanding of
steam distribution (e.g., headers, pressure let down, steam traps, and condensate recovery). Instrument Air - Understanding of
instrument air fundamentals (e.g., compression, dewpoint, filtration, system
pressure) and instrument air systems (e.g., dryers,
filters, cycles, compressors, desiccant filters, switching, receivers, KO
pots, back-ups – N2 utility air). Utility Air - Understanding of utility
air fundamentals (e.g., higher pressure and moisture content than instrument
air, compression, uses-pneumatics,
atomization, waste treatment) and utility air systems (e.g., filters,
compressors, headers, manifolds, and back-ups). Material Sampling - Knowledge of sampling
techniques and of proper labeling procedures for samples collected. Quality Assurance - Interpret and verify
quality (e.g., certificate of analysis) and quantity when receiving
materials. Hazard Labeling - Knowledge of standard
labeling systems (e.g., NFPA for equipment). Equipment Monitoring - Conduct physical
inspections of equipment (e.g., tanks, pipes, drums, pumps, vents, and safety
equipment). Inventory Control - Knowledge of inventory
control fundamentals and its impact. PPE - Knowledge of personal protective
equipment and their appropriate use. Safety Equipment Operations Knowledge of
operating safety equipment. Boiler Feed Water - Understanding of
boiler feed water fundamentals (e.g., pressures, phase change/flash point,
uses, sources, makeups, chemical treatment, hydrology) and boiler feed water
systems (e.g., dearators, softeners, accumulators, demins, blow downs,
condensate return). Steam Condensate - Understanding of
condensate fundamentals (e.g., condensate purity, system pressure, uses,
sources) and condensate systems (e.g., flash tanks, drain pots, desuper
heater, steam traps, analyzers, let down stations). Natural Gas - Understanding of natural
gas fundamentals (e.g., properties & chemistry of natural gas, uses -
blanketing, fuel, processes, sources - local utilities, pipelines) and
natural gas systems (e.g., pilot gas, compressors, regulators, KO pots,
emergency shut downs). Fuels - Understanding of fuel
fundamentals—liquids, solids, and gases (e.g., sources, types, fluctuations
in make-up, BTU) and fuel system components (e.g., regulators, knockouts,
mixing areas, scrubbers, back-up systems, vaporizers, atomizers, conveyors). Nitrogen - Understanding of nitrogen
fundamentals (e.g., inert, properties, hazards, uses, sources) and nitrogen
systems (e.g., regulators, knock-out pots, generators-varies by site,
compressors, analyzers, O2 content). Water Systems - Understanding of
fundamentals of water systems (e.g., potable, process, utility, fire,
service, storm, waste) and water system components (e.g., filtration,
clarification, tanks, aeration, reverse osmosis, demineralization, and
deionization). |
Drums Hoses Compressors Extruders Flares Boilers Cryogenic unit Economizer Switch gears Skimmers Steam traps Gloves Respirator Acid suit Ear muffs SCBA (Self-Contained Breathing Apparatus) Face shield Motor control centers Reverse osmosis unit Safety goggles/glasses Drum dolly Pumps (centrifugal, vacuum, positive
displacement) Drivers (such as electrical motors, steam
turbines, gas turbines, air drivers) Piping Scrubbers Valves Filters Demisters Condenser Generators Transformers Aerators Clarifiers Fork lift Hand truck Slicker suit Hard hat Eyewash fountain FRCs (Flame Retardant Clothing) Thermal suit Furnaces/fired heaters Fire extinguisher Metatarsal guard Control valve (regulator) Instrumentation (analyzers, gauges,
control loops, temperature sensing devices) Tools (such as sample thief, strapping
tape, pipe wrench, channel locks, valve wrenches) Tubing Tanks Resins Cooling towers Dryers Eductors Meters Incinerator Basins pH meters Superheaters Safety boots Ear plugs Safety shower First aid kit Fire monitors Tower (tray, packed) API separators/traps Microfiltration equipment Desuperheaters Heat exchangers (coolers, reboilers,
fans) Heat recovery steam generator (waste heat
boiler) Reactors (batch stirred tank or
continuous stirred tank, fixed bed catalyst or fluidized be catalyst) Fittings Safety harness Personal lift Computers UPS (uninterruptible power source |