Master Curriculum

Petrochemical & Process Plant Operator Training

(Beginner to Expert)

🔰 LEVEL 1 — BEGINNER (FOUNDATION)

1️⃣ INTRODUCTION TO PROCESS PLANT

Goal: Understand the big picture of a plant

• What is:

  • Petrochemical plant

  • Oil & Gas plant

  • Chemical plant

• Upstream, Midstream, Downstream (basic)

• General plant flow:

  • Feed → Process → Product

• Main plant areas:

  • Process Area

  • Utility Area

  • Tank Farm

  • Control Room

• Operator roles:

  • Field Operator

  • Panel Operator

  • Utility Operator

  • Operation vs Maintenance

2️⃣ BASIC PROCESS & ENGINEERING CONCEPT

Goal: Basic process understanding

• Basic process variables:

  • Flow

  • Pressure

  • Temperature

  • Level

• PFD vs P&ID (operator level)

• Lines, valves, and equipment overview

• Normal vs abnormal operation

• Start-up, shutdown, emergency (basic idea)

3️⃣ BASIC SAFETY AWARENESS

Goal: Build safety mindset

• Why process plants are dangerous

• Types of hazards:

  • Mechanical

  • Chemical

  • Thermal

  • Electrical

• Accident, Incident, Near Miss

• Safety culture & responsibility

• Stop Work Authority (SWA)

4️⃣ PERSONAL PROTECTIVE EQUIPMENT (PPE)

Safety > PPE

• Helmet, goggles, face shield

• Gloves (types and usage)

• Safety shoes

• Coverall / FR clothing

• Respirator & SCBA

• When PPE is mandatory

🟢 LEVEL 2 — BASIC OPERATOR SKILLS

5️⃣ PROCESS EQUIPMENT OVERVIEW

A. Static Equipment

• Vessels

• Columns / Towers

• Heat Exchangers

• Tanks

• Reactors (basic concept)

B. Rotating Equipment

• Pumps

• Compressors

• Fans & Blowers

• Turbines

6️⃣ PUMP SYSTEMS

Equipment > Pumps

• Pump function

• Pump types:

  • Centrifugal

  • Positive Displacement

• Main pump parts

• Mechanical seal & bearings

• Suction & discharge concept

• Common problems:

  • Cavitation

  • Seal leakage

  • Vibration

• Basic operator troubleshooting

7️⃣ COMPRESSOR SYSTEMS

• Compressor function

• Compressor types:

  • Centrifugal

  • Reciprocating

  • Screw

• Anti-surge (simple explanation)

• Lubrication oil system

• Common alarms and trips

8️⃣ HEAT TRANSFER EQUIPMENT

• Heat exchanger basics

• Shell & tube exchanger

• Air cooler

• Fouling and performance

• Operator inspection points

9️⃣ VALVES & PIPING

• Valve types:

  • Gate

  • Globe

  • Ball

  • Control valve

• Manual vs control valve

• Piping color code & line marking

• Normally Open (NO) / Normally Closed (NC)

🟡 LEVEL 3 — OPERATION & CONTROL

🔟 BASIC INSTRUMENTATION

• Pressure, Temperature, Flow, Level instruments

• Indicator vs Transmitter

• Basic control loop concept

• PID (simple operator view)

• Alarms and interlocks

• Manual vs Auto mode

1️⃣1️⃣ CONTROL ROOM OPERATION

• Panel operator role

• Reading trends

• Normal operating range

• Alarm handling

• Communication with field operator

1️⃣2️⃣ START-UP & SHUTDOWN OPERATIONS

• Start-up philosophy

• Pre-start checklist

• Equipment line-up

• Cold start vs hot start

• Normal shutdown vs emergency shutdown

1️⃣3️⃣ ABNORMAL & EMERGENCY OPERATION

• Process upset conditions

• Utility failure

• High pressure / temperature events

• Process leaks

• Emergency response basics

🔵 LEVEL 4 — SAFETY, PERMIT & PROCESS SAFETY

1️⃣4️⃣ PERMIT TO WORK (PTW)

Safety > Permit

• What is Permit to Work

• Types of permits:

  • Hot Work

  • Cold Work

  • Confined Space Entry

  • Working at Height

  • Electrical work

• Lock Out Tag Out (LOTO)

• Gas testing & isolation

1️⃣5️⃣ PROCESS SAFETY MANAGEMENT (OPERATOR LEVEL)

• Hazard vs Risk

• HAZOP (operator understanding)

• Safety Integrity Level (SIL)

• Interlocks and trips

• Safety critical equipment

1️⃣6️⃣ FIRE & GAS SYSTEMS

• Fire triangle

• Gas detection system

• Flame detection

• Fire water system

• Fire extinguisher types & usage

🟣 LEVEL 5 — UTILITY SYSTEMS

1️⃣7️⃣ UTILITY SYSTEM OVERVIEW

• Why utilities are critical

• Utility impact on process plant

1️⃣8️⃣ STEAM & BOILER SYSTEMS

• Boiler basics

• Steam distribution

• Condensate system

• Steam traps

• Steam hazards

1️⃣9️⃣ COOLING WATER & CHILLED WATER

• Cooling tower

• Heat rejection concept

• Water quality basics

• Common operating problems

2️⃣0️⃣ ELECTRICAL & POWER SYSTEMS (OPERATOR VIEW)

• Power generation & distribution

• MCC

• UPS & emergency power

• Blackout scenario

2️⃣1️⃣ INSTRUMENT AIR & NITROGEN SYSTEMS

• Air compressor system

• Air dryer

• Instrument air failure impact

• Nitrogen usage & safety

🔴 LEVEL 6 — ENVIRONMENT, HEALTH & HUMAN FACTORS

2️⃣2️⃣ ENVIRONMENTAL MANAGEMENT

• Air emissions

• Liquid effluent

• Solid & hazardous waste

• Spill prevention & control

2️⃣3️⃣ OCCUPATIONAL HEALTH

• Chemical exposure

• Noise hazard

• Heat stress

• Fatigue management

2️⃣4️⃣ HUMAN FACTORS & COMMUNICATION

• Shift handover best practice

• Logbook usage

• Procedure compliance

• Situational awareness

⚫ LEVEL 7 — ADVANCED / EXPERT OPERATOR

2️⃣5️⃣ TROUBLESHOOTING METHODOLOGY

• Structured problem solving

• Symptoms vs root cause

• Decision making under pressure

2️⃣6️⃣ MAJOR PROCESS INCIDENT CASE STUDIES

• Fire

• Explosion

• Toxic release

• Operator lessons learned

2️⃣7️⃣ OPERATOR EXCELLENCE & LEADERSHIP

• Best operating practices

• Coaching junior operators

• Continuous improvement mindset

• Safety leadership