Module 5 – Operating Practices & Procedures

Objective:
By the end of this module, a trainee will be able to:

1. Understand standard operating procedures (SOP) for safe plant operation.

2. Identify pre-start, startup, normal operation, and shutdown practices.

3. Learn proper sampling and analytical monitoring practices.

4. Understand the importance of logging, reporting, and documentation.

5. Apply best practices for troubleshooting and routine checks.

5.1 – Introduction to Operating Practices

Definition:

• Operating practices are structured methods to run a plant safely and efficiently.

• SOPs ensure consistency, safety, and compliance.

Key Principles:

1. Always Follow SOPs: prevent accidents and process upsets.

2. Observation & Awareness: constant monitoring is critical.

3. Communication: shifts handover, logbooks, and alarms.

4. Safety First: never bypass interlocks, alarms, or safety systems.

Analogy:

• Operating a plant is like piloting a complex airplane: pre-flight checks, monitoring during flight, and safe landing procedures.

5.2 – Pre-Start Checks (Conceptual)

Purpose:

• Ensure all systems are ready for safe startup.

Typical Checks:

1. Mechanical & Electrical Equipment:

   • Pumps, compressors, heat exchangers: check alignment, lubrication, valves.

   • Electrical panels: verify breakers, alarms, and indicator lights.

2. Utilities:

   • Steam, cooling water, nitrogen, instrument air, and electricity: check availability and flow.

3. Instrumentation & Control Systems:

   • Calibrate instruments, verify control loops.

   • Check alarms and interlocks.

4. Safety Systems:

   • Fire, gas detection, emergency shutdown (ESD), flare system functional.

5. Housekeeping:

   • Walk the plant for leaks, obstructions, or hazards.

   • Verify PPE and tools availability.

Operator Tips:

• Use pre-start checklists.

• Record deviations and resolve before startup.

5.3 – Startup Procedures (Conceptual)

Objective:

• Bring the plant from idle to normal operation safely and efficiently.

Conceptual Steps:

1. Initiate Utilities: verify steam, cooling water, instrument air, and nitrogen supply.

2. Start Pumps & Compressors: follow duty/standby sequence.

3. Gradually Introduce Feed: monitor pressure, temperature, and flow carefully.

4. Reactors & Separation Units: bring units online gradually to avoid thermal shocks or overpressure.

5. Monitor Alarms & KPIs: ensure process variables stay within safe operating ranges.

Operator Tips:

• Avoid sudden changes in flow or temperature.

• Confirm control loops respond correctly.

• Maintain communication with control room and other operators.

Analogy:

• Startup = “warming up a car engine before driving long distances.”

5.4 – Normal Operation

Responsibilities During Normal Operation:

1. Continuous Monitoring:

   • Pressure, temperature, flow, level, alarms.

2. Field Inspections:

   • Check pumps, compressors, valves, strainer conditions, and leaks.

3. Sampling & Analysis:

   • Collect samples safely for quality monitoring.

   • Check basic indicators like color, odor, or density.

4. Communication & Logging:

   • Record readings, incidents, and maintenance requests.

   • Handover to next shift with notes on abnormal trends.

Best Practices:

• Observe abnormal noise, vibration, or smells.

• Don’t bypass safety interlocks.

• Maintain clean and organized work area.

Analogy:

• Normal operation = “driving on a highway”: maintain speed, monitor gauges, respond to obstacles.

5.5 – Shutdown Procedures (Conceptual)

Objective:

• Bring the plant or units to safe idle or off status.

Conceptual Steps:

1. Stop Feed & Reactors: gradually reduce flow and temperature.

2. Isolate Units: close valves, shut pumps/compressors in sequence.

3. Drain/Depressurize Lines (if required): follow SOPs.

4. Utilities: reduce or isolate as needed.

5. Final Checks: verify safe pressure, temperature, and tank levels.

6. Log Shutdown: record readings, anomalies, and maintenance needs.

Operator Tips:

• Follow sequence strictly.

• Watch for abnormal pressures or temperature spikes during shutdown.

• Verify alarms and ESD status before leaving.

Analogy:

• Shutdown = “turning off a factory at the end of the day”: orderly, safe, and documented.

5.6 – Sampling & Analytical Monitoring

Purpose:

• Ensure product quality and process stability.

Operator Concepts:

• Follow sampling SOPs: safe point, proper container, PPE.

• Observe physical properties (color, clarity, odor).

• Record sample data in logbooks.

Safety Notes:

• Butadiene and other chemicals are flammable and toxic.

• Never open sampling points without authorization.

• Use nitrogen purge or closed-loop systems if applicable.

Analogy:

• Sampling = “checking the taste and color of soup while cooking” to ensure correct recipe.

5.7 – Recordkeeping & Documentation

Purpose:

• Accurate records ensure traceability, compliance, and operational insight.

Operator Responsibilities:

1. Log readings, alarms, deviations, and maintenance activities.

2. Note abnormal observations, even if resolved.

3. Record handover notes for next shift.

4. Maintain digital or physical logbooks per company policy.

Operator Tips:

• Be accurate and timely.

• Include context, e.g., “pressure increased after startup ramp, normalized after valve adjustment.”

Analogy:

• Logbook = “black box in an airplane,” capturing events for safety and troubleshooting.

5.8 – Basic Troubleshooting Principles (Conceptual)

Conceptual Steps:

1. Observe: abnormal readings, noises, vibrations, leaks, or smells.

2. Verify: confirm instrument accuracy, check panel indications.

3. Analyze: compare with normal operating trends and checklists.

4. Respond: adjust controls if safe, notify supervisor if beyond scope.

5. Document: record actions, observations, and outcomes.

Best Practices:

• Don’t guess or bypass safety systems.

• Use SOPs, troubleshooting guides, and senior support.

• Learn from each incident to prevent recurrence.

Analogy:

• Troubleshooting = “detective work”: observe clues, verify facts, act safely.

5.9 – Quiz / Knowledge Check

1. What are the main steps in pre-start checks?

2. Name two key responsibilities during normal operation.

3. Why is gradual startup important?

4. List three points to observe during shutdown.

5. Explain the importance of proper sampling and handling.

6. Why is recordkeeping critical for operators?

5.10 – Media Sites Integration

• Videos:

  • Pre-start and startup demo animation (conceptual)

  • Field round monitoring walkthrough

  • Sample collection demo (generic and safe)

  • Shutdown sequence overview

• Diagrams:

  • Pre-start/startup/shutdown flowcharts

  • Operator observation and checklist points

• PDFs / Checklists:

  • Pre-start and startup checklist

  • Normal operation field round checklist

  • Sampling SOP template

  • Logbook template

• Interactive:

  • Embedded quizzes and reflection exercises

5.11 – Summary & Key Takeaways

1. Operators must follow SOPs strictly for pre-start, startup, normal operation, and shutdown.

2. Observation, monitoring, and safe intervention are key skills.

3. Sampling ensures product quality and process stability.

4. Accurate recordkeeping and logging are essential for traceability and safety.

5. Troubleshooting is observation-driven and safety-first, never bypassing alarms or interlocks.