【20090811 Key Topic】What qualifications are needed to become an excellent chemical operator?

The key is to be proficient in operations and technical skills, to be able to draw analogies, and to handle special situations promptly

A good chemical operator possesses the necessary basic theories, becomes familiar with the operations under their guidance, and is able to apply these theories to address problems that arise during the production process.

First, pay attention to your own safety and the safety of others； Second, be bold yet cautious, and ask why more often ； Third, find a book on chemical engineering design; it’s best to not only understand how to carry out the tasks but also know why things are designed that way and whether the design is good or not

This post was last edited by zhangyong6404 on 2009-8-10 at 17:33. Your question is too broad; it’s really difficult to answer. Here are the requirements related to chemical engineering skill assessment – if you can meet them, it’s certain that you’ll become an excellent chemical operator. 1. Junior Plant Operator 1.1 Knowledge Requirements 1.1.1 Basic Process Knowledge (1) Understand the basic principles and characteristics of the reactions and unit operations associated with this position. (2) Be familiar with the process flow of this position that includes control points, the locations and functions of the main valves and pipelines, as well as the name, flow direction, and purpose of the operating medium. (3) Be familiar with the process technical specifications, operating procedures, start-up and shutdown steps, control parameters, and handling of abnormal conditions for this position. (4) Be familiar with the basic keyboard operation functions of the DCS for this position, as well as knowledge regarding screen display, trend visualization, and adjustment of control loops. (5) Understand the control conditions for process parameters. (6) Understand the operation methods for starting and stopping the machines and pumps in this system, as well as the knowledge related to equipment maintenance. (7) Be familiar with the inspection routes, contents, and methods for this position. 1.1.2 Basic Knowledge of Equipment (1) Be familiar with the structure, functions, characteristics, materials, and operating conditions of the main equipment in this position. (2) Understand the structure, performance, the contents and meaning indicated on the nameplates, as well as the usage knowledge of various pumps and machinery within the system. (3) Understand the types, specifications, and application ranges of common flanges, valves, and gaskets. (4) Be familiar with the basic knowledge of instrument control for this position, as well as the locations of control points and the proper methods of using them. (5) Understand the types of electrical equipment used in this position and the knowledge on their proper use. (6) Be familiar with the specifications, types, and usage knowledge of common lubricants for pumps. (7) Understand the key points and basic knowledge of equipment maintenance for this position. (8) Understand the general knowledge regarding the safe replacement and maintenance of equipment and pipelines. 1.1.3 Basic knowledge of raw and auxiliary materials (1) Master the physical and chemical properties of raw materials as well as various parameters related to reactions. (2) Understand the main parameters and operations of the three types of agents and utility systems ； (3) Understand the names of the analysis items, quality parameters for raw and auxiliary materials, as well as the meaning of each parameter. (4) Understand the impact of quality changes in raw and auxiliary materials on the manufacturing process. 1.1.4 Basic Knowledge of Product Quality (1) Understand the quality standards and analysis items of products, as well as the number of analyses and control parameters during the manufacturing process. (2) Understand the factors and conditions that affect the quality of products, intermediate products, and by-products. (3) Master the basic knowledge of quality management. 1.1.5 Basic Theoretical Knowledge (1) Master the basic concepts and knowledge of mathematics, physics, and chemistry that are commonly used in production technology. (2) Understand the mechanisms of reactions and unit operations, as well as basic knowledge in introductory chemical engineering. 1.1.6 Safety and environmental protection knowledge (1) Be familiar with various rules and regulations regarding safe production. (2) Be familiar with the flammability and strong corrosiveness of the materials, as well as the first-aid measures in case of poisoning. (3) Be familiar with the purposes and correct usage methods of fire-fighting and protective equipment. (4) Be familiar with the fire prevention, explosion prevention, poison prevention measures, as well as the key preventive and emergency response measures for this position. (5) Be familiar with the relevant regulations on sewage, oily waste, and exhaust gas emissions, as well as the environmental protection laws and regulations. (6) Be familiar with the occupational hazard factors, their characteristics, and the industrial hygiene standards present in the workplace and during the production process. (7) Be familiar with safe electricity usage and the operation of common electrical appliances. 1.1.7 Technical management and knowledge of new technologies (1) Be familiar with the aspects of on-site management and technical management related to this position. (2) Understand the contents of team economic accounting. (3) Understand the technical improvement measures and technical development directions of this device. 1.2 Skill Requirements 1.2.1 Process Operation Skills (1) Ability to carry out the normal operation of key processes in accordance with the requirements of process technical specifications, operating procedures, and process cards, as well as to adjust parameters such as reaction temperature, tower liquid level, tower temperature, and tower pressure. Capable of operating equipment and adjusting utility systems. (2) Be able to become proficient in system adjustment and adjust the parameters of the oxidation reaction based on central control analysis. (3) Be able to properly start and reset the interlock system and automatic protection system, as well as carry out operations such as starting, stopping, switching, and emptying various pumps. (4) It allows for adjustment of the input amount of various materials. (5) Be familiar with the cooling and lubrication conditions of various machines and pumps, and be able to handle them properly. (6) It enables online control of computer screen display, and allows adjustments to the control loop based on trend visualization. (7) Able to conduct on-site inspections as required. 1.2.2 Equipment operation and maintenance capabilities: (1) Be able to identify and know the location, name, and purpose of the equipment, instrument control points, important valves, flanges, and pipelines in one’s own position. (2) Be able to start, stop, and operate the pump in accordance with the prescribed procedures, as well as add lubricant regularly and carry out maintenance. (3) Be able to use maintenance tools correctly. (4) Capable of performing tasks such as emptying materials, purging, and replacement before equipment maintenance, as well as providing supervision during the maintenance process. (5) Capable of carrying out simple equipment maintenance tasks such as replacement, leak testing, pressure testing after the maintenance of equipment and pipelines, as well as general leak repairs, gasket replacement, installation of blind flanges, and filter replacement. (6) Be able to use instruments and electrical equipment correctly. 1.2.3 Accident identification, handling, and response capability: (1) The ability to promptly detect and address any abnormalities in the manufacturing processes or equipment operation within one’s own role. (2) Be able to correctly determine whether various instruments in this position (flow, pressure, temperature, level) are operating properly, and be able to distinguish between process fluctuations and instrument-related fluctuations. (3) Be able to properly handle emergencies such as interruptions in water, electricity, steam, the raw material propylene, air, and deionized water, in accordance with the process technical specifications, operating procedures, and process cards. (4) Able to handle various abnormalities and routine accidents in this position. (5) Be able to use safety and fire-fighting equipment correctly. 2.2.4 Drawing and calculation capabilities: (1) Able to draw process flow diagrams for one’s own position and understand equipment schematics. (2) Able to perform simple calculations for the material balance and heat balance of this position. (3) It is capable of calculating conversion rates, yields, etc., based on the relevant data from the analysis report. 2.2.5 Technical management and innovation capabilities (1) Ability to fill in operation records and shift handover logs correctly. (2) Able to participate in team quality management and economic accounting activities. (3) Able to propose suggestions for improving the process technology of this position. (4) Able to participate in various activities related to technological innovation. 2 Intermediate Equipment Operator 2.1 Knowledge Requirements 2.1.1 Basic Process Knowledge (1) Master the basic principles and relevant theoretical knowledge of this position. (2) Master the adjustment of process fluctuations caused by changes in process parameters. (3) Master the process technical specifications of this device, be familiar with the operating methods of adjacent positions, as well as the startup, shutdown procedures and special operation methods for each process in the system. (4) Understand the technological processes of adjacent positions with control points, as well as the properties of on-site equipment and various materials. (5) Be familiar with the basic knowledge of material balance and heat balance. (6) Be familiar with the routes, contents, and methods of routine inspections for each process of the equipment. (7) Be familiar with various process technology management and adjustment knowledge related to the plant’s DCS. (8) Understand the basic working principles of the plant’s pumps, instruments, and protective devices. (9) Be familiar with the sources, consumption amounts, grades, control parameters, and other relevant information regarding the utility systems of the facility. 2.1.2 Basic Knowledge of Equipment (1) Be familiar with the working principles and special properties of the main equipment in this unit. (2) Be familiar with the structure, characteristics, and material selection of reactors, as well as various types of towers, pumps, and heat exchangers used in this position. (3) Understand the operating conditions of the pumps inside the device and their various driving principles. (4) Be familiar with the knowledge on troubleshooting common failure points in related positions. (5) Understand the basic knowledge of mechanical seals. (6) Understand the basic knowledge of corrosion and anti-corrosion ； . (7) Understand the contents and technical requirements for the maintenance of this equipment, as well as the acceptance procedures and standards after maintenance. (8) Be familiar with the operating principles of the instrument control for this device, as well as various knowledge related to its operation and adjustment. (9) Understand the simple working principle of the electrical components in this device. 2.1.3 Basic knowledge of raw and auxiliary materials (1) Master the physical and chemical properties of raw and auxiliary materials, as well as various parameters related to their reactions. As well as the basis for setting various parameters. (2) Understand the impact of various process parameters on product quality. (3) Be familiar with the types, physical and chemical properties, as well as applicable conditions and scope of the three agents. (4) Be familiar with the content of analysis items for raw and auxiliary materials, the scope of control, analysis methods, as well as the impact of changes in quality parameters on the manufacturing process and the measures to be taken. (5) Understanding of the impact of various process parameters on the reaction and knowledge of how to make adjustments. 2.1.4 Product Quality Knowledge (1) Master the content of quality analysis for products, intermediate products, and by-products. (2) Understand the meaning of the quality control parameters for products and intermediate products, as well as the means and methods for adjusting quality. (3) Master the basic knowledge of quality management. 2.1.5 Basic theoretical knowledge (1) Master the general knowledge regarding mass transfer and heat transfer. (2) Familiar with fluid mechanics in chemical processes, liquid and gas transfer, and aware of general theoretical knowledge such as absorption. 2.1.6 Safety and environmental protection knowledge (1) Understand the ignition point and explosion limit of raw materials, as well as their toxicity and corrosivity, and know the first aid measures in case of poisoning. (2) Be familiar with the alarm and interlock values among the various control parameters of this device. (3) Be familiar with the principles, mechanisms, and methods of waste treatment for the three types of waste generated by the facility, as well as the relevant emission standards and regulations. (4) Be familiar with the locations for environmental sampling of the equipment and the contents of the analysis items. (5) Be familiar with the occupational hazard factors, their nature, and the industrial hygiene standards present in the workplace and during the production process. 2.1.7 Technical Management and New Technology Knowledge (1) Master the content and methods of technical management for one’s position. (2) Master the statistical and calculation methods for team economic accounting. 2.2 Skill Requirements 2.2.1 Process Operation Capability (1) Able to carry out the normal operation of the plant as well as its startup and shutdown. (2) Able to skillfully adjust the process operations caused by factors such as changes in the raw material composition and steam pressure within the system. (3) Be able to determine the reasons for product non-conformity based on the analysis results from the central control system, and carry out comprehensive adjustments accordingly to ensure that the products meet the standards as soon as possible. (4) Able to carry out device shutdown and leak detection tasks proficiently, with a basic understanding of the instruments in automatic interlock and alarm systems, and capable of handling minor faults. (5) Capable of adjusting some functions of the DCS, diagnosing and handling simple faults, as well as performing printing tasks. 2.2.2 Equipment operation and maintenance capabilities: (1) Able to guide the tasks of system evacuation, replacement, purging, pressure testing, inspection, and acceptance before and after major equipment overhauls. (2) Be able to identify problems in equipment maintenance in a timely manner and take remedial actions. (3) Be able to correctly identify the location of common equipment failures and take timely action to address them. (4) Be able to carry out maintenance work on general non-transmission equipment and troubleshoot common equipment faults with the assistance of relevant specialists. (5) It is capable of adjusting certain instrument parameters, as well as handling common issues such as pressure measurement points and regulators. 2.2.3 Accident judgment, handling, and response capability: (1) Able to handle promptly and correctly emergencies such as power outages, shortages of water, steam, hydrogen, and demineralized water in this device. (2) Be able to correctly analyze and determine the causes of abnormal operation of this device, and take timely measures based on operational data to restore it to normal operation. (3) It is capable of taking appropriate measures to handle various emergencies such as material leakage and fires involving this device. (4) Be able to conduct safety and potential accident hazard inspections on this device, and propose corrective measures. 2.2.4 Drawing and calculation capabilities: (1) Able to draw process flow diagrams for entire systems, and understand general process piping diagrams and general equipment assembly drawings. (2) It is capable of performing simple heat balance calculations and material balance calculations for this device. 2.2.5 Technical management refers to the ability to innovate: (1) The ability to organize quality management activities and various tasks within teams, as well as to conduct statistics on relevant data, organize it, and prepare management charts. (2) Be able to propose rationalization suggestions for improving production and participate in the implementation of technical improvement plans. (3) Able to carry out economic accounting for work teams and prepare relevant accounting reports. 3 Senior Operators 3.1 Knowledge Requirements 3.1.1 Basic Process Knowledge (1) Have a thorough understanding of the characteristics and principles of the reactions and unit operations involved in this facility. (2) Master the operating principles and methods of this type of work, and be familiar with the basis for formulating technical procedures. (3) Be familiar with the principles of material balance and heat balance in the plant, the difficulties in achieving balance, and the measures to be taken. (4) Understand the configuration of various functions of the plant’s DCS, and master the knowledge related to the adjustment of these functions. (5) Understand the process and technical characteristics of other domestic installations. 3.1.2 Basic Knowledge of Equipment (1) Understand the structure, performance, functions, models, materials, and operating conditions of all equipment in this system, as well as the service life of each piece of equipment, the tasks required for maintenance, and the technical specifications. (2) Understand the application scope and selection principles of fixed-type equipment such as pumps, as well as the basic knowledge of mechanical seals. (3) Master the basic knowledge of mechanical lubrication, as well as the applicable ranges and conditions for various lubricants. (4) Be familiar with the selection principles and assembly technical requirements for valves, flanges, pipes, pipe fittings, and gaskets, as well as the basic knowledge of corrosion protection and insulation. (5) Be familiar with the operating principles of the electrical equipment in this device and general maintenance knowledge. (6) Understand the similarities and differences between domestic similar units and this unit, the advantages and disadvantages of various equipment, as well as the localization, improvements, and development status of the main equipment used in propylene oxidation and absorption in China. 3.1.3 Basic knowledge of raw and auxiliary materials (1) Master the physical and chemical properties of raw and auxiliary materials as well as various parameters related to their reactions. As well as the basis for setting various parameters. (2) Understand the impact of various process parameters on product quality. (3) Be familiar with the types, physical and chemical properties, as well as applicable conditions and scope of the three agents. (4) Be familiar with the content of analysis items for raw and auxiliary materials, the scope of control, analysis methods, as well as the impact of changes in quality parameters on the manufacturing process and the measures to be taken. (5) Understanding of the impact of various process parameters on the reaction and knowledge of how to make adjustments. 3.1.4 Product Quality Knowledge (1) Understand the basis for establishing quality standards for various products and intermediates, as well as the content of these standards. (2) Be familiar with the conditions required to ensure the quality of products and intermediates. (3) Understand the regulations and policies regarding product quality. 3.1.5 Basic theoretical knowledge: (1) Master chemical engineering theoretical knowledge at a secondary vocational school level. (2) Be familiar with the basic theoretical knowledge of reaction kinetics, catalytic theory, and fluid dynamics related to the oxidation of propylene to produce acrylic acid and catalytic combustion. (3) Master the general calculation methods for mass transfer and heat transfer. 3.1.6 Safety and environmental protection knowledge: (1) Be familiar with the regulations regarding safe production and the criteria used for formulating such regulations; (2) Understand the properties and safety parameters of all materials used in this device. (3) Understand the basic theories and regulations related to environmental protection, and master the common methods for treating waste water, waste gas, and waste solids. 3.1.7 Technical Management and New Technology Knowledge (1) Master the basic knowledge of device optimization operations. (2) Understand the development trends in aspects such as processes, equipment, and automatic control technology for similar devices at home and abroad. 3.2 Skill Requirements 3.2.1 Process Operation Skills (1) Able to guide the start-up and shutdown of the plant, as well as to handle various abnormal situations. (2) Able to participate in formulating start-up and shutdown plans for the equipment and guide their proper implementation. (3) Able to participate in the joint commissioning of similar devices and the commissioning with chemical feedstock. (4) Able to participate in the acceptance and commissioning work following technical upgrades of the installation and equipment replacements. (5) Able to participate in ensuring the equipment meets standards, carrying out optimization efforts, and engaging in daily production activities, as well as contributing to the development of plans for such standardization and optimization. (6) Able to participate in the formulation, modification, and preparation of operating methods, process technical specifications, and process cards. 3.2.2 Equipment maintenance capabilities: (1) Able to guide the preparatory work prior to annual major overhauls, the coordination work during these overhauls, and the inspection work afterward. (2) Be able to propose major and medium-scale equipment maintenance projects as well as improvement suggestions based on the actual operating conditions of the equipment. (3) Be able to promptly detect operational faults in equipment, instruments, electrical appliances, etc., and carry out corresponding repairs or minor maintenance work. 3.2.3 Accident judgment, handling, and response capability: (1) Able to guide relevant personnel in properly handling major accidents that occur in the equipment, as well as analyze the causes of such accidents and propose preventive measures. (2) Be able to promptly identify and eliminate potential accident hazards, and propose measures for handling and improvement. (3) Be able to propose and organize decisions regarding the switching or shutdown of machines and pumps, as well as the start-up and shutdown of the system, in response to unexpected situations on site. 3.2.4 Drawing and calculation capabilities: (1) Capable of drawing device diagrams as well as general part drawings. (2) Able to understand general construction piping diagrams and instrument interlock diagrams. (3) Be able to perform simple calculations for heat and mass transfer. (4) Able to draw process-related drawings for technical upgrades and improvements. 3.2.5 Technical Management and Innovation Capability (1) Able to organize and apply modern management and quality control methods, carry out various management tasks related to this device in light of actual production conditions, identify issues, and organize their implementation. (2) Be able to put forward reasonable suggestions and plans that meet practical requirements. (3) Able to prevent the team’s economic accounting work and guide senior and intermediate workers in conducting economic analyses of production activities. (4) Able to organize the preparation of production and technical summaries. (5) Able to organize and guide the team’s professional training.

In short, you first need to understand the properties of the medium, under what conditions it will burn or explode, and where accidents are likely to occur. It’s important to be well aware of the areas in the site where accidents are likely to happen, as well as the processes and operations involved. The key is to ensure both personal safety and safety in production

The key is to master the operations and skilled techniques – keep working hard! ~

Familiar with the process flow, understand the principles of equipment, know how to handle emergencies, and strictly adhere to operating procedures and process specifications.

First, you need to understand your responsibilities and what constitutes safe and proper practices. Is there a better approach based on safety standards? Secondly, start by understanding the basic properties of the materials involved in your own process; by proceeding step by step in this manner, one day when you look back, ah! I’ve made such great progress! Also: No matter what you do, always keep your mind clear, and from time to time step back from what you’re doing to examine yourself as a bystander.

5# zhangyong6404 It’s so detailed; it will last a lifetime :lol

No matter which company you work for, safety must be the top priority, and the principle of “not harming oneself, others, or the environment” should be followed”； Secondly, mastering various operational skills: this requires a longer period of experience accumulation ； In the work process, one should first think, then act, and finally summarize ； Before starting work, think in advance about whether what I am about to do is feasible, what potential risks there are, whether it complies with our work standards, whether all my precautions have been taken, what unexpected situations might arise during the work, and how I should deal with them. While working, consider whether my approach is correct ； After completing the tasks, take some time to summarize today’s work: in which areas did I perform well, where were my shortcomings, and are there any better ways to approach things? ；