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Intro to Chemical Manufacturing

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Module: Operator Duties & Responsibilities / Role of the Chemical Process Operator

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Glossary

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control room

Where the distributed control system and other remote process control equipment is located.

control room operator

The chemical operator who is responsible for using the DCS to monitor and adjust the process for safe production that meets quality standards.

Distributed Control System (DCS)

The networked computer system that allows operational personnel to monitor the overall process.

field

Where process equipment is located.

field operator

The chemical operator who is responsible for ensuring that the equipment used in a process is working properly.

Finished Product Area

The area of a chemical plant where finished product is stored and off loaded for transporting to customers.

Production Area

The area of a chemical manufacturing plant where raw materials are turned into finished product. In some plants, the production area is divided into process units.

Raw Material Storage Area

The area of a chemical plant where raw materials are stored after being received.

Receiving Area

The area of a chemical manufacturing plant where raw materials are received and off loaded.

unit

A division of the chemical manufacturing production area designed and equipped to produce one product or family of products.

Chemical Facility Anti-Terrorism Standards (CFATS)

The legislation that authorizes the Department of Homeland Security to impose federal security regulations for high-risk chemical facilities.

Clean Air Act (CAA)

The legislation that authorizes the EPA to set standards for toxic air pollutants. The Clean Air Act requires chemical manufacturing facilities to install pollution control equipment, meet specific emissions limitations, and obtain operating permits.

Clean Water Act (CWA)

The primary federal law that regulates water pollution. The CWA sets and enforces standards to reduce the amount of potation released into waterways.

Department of Homeland Security (DHS)

The cabinet department of the federal government that is responsible for protecting the United States from terrorist attacks and responding to natural disasters. DHS sets standards and enforces regulations that ensure the security of chemical facilities.

Department of Transportation (DOT)

The federal agency that is responsible for ensuring the safety of the United States transportation system. DOT oversees the safe shipment of hazardous materials by air, road, rail, or water.

Environmental Protection Agency (EPA)

The federal agency that is responsible for setting and enforcing standards to protect the environment from pollution.

Food and Drug Administration (FDA)

The federal agency that is responsible for protecting public health by assuring the safety, efficacy, and security of human and veterinary drugs, biological products, medical devices, food supply in the United States, cosmetics, and products that emit radiation.

Hazard Communication Standard (HAZCOM)

The OSHA standard that requires employers to employers to inform employees about hazardous chemical information. HAZCOM requires communicating with employees by providing material safety data sheets (MSDS), training, and a comprehensive safety program. (OSHA 29 CFR1910.1200)

Hazardous Waste Operations and Emergency Response (HAZWOPER)

The OSHA standard that requires employers to create a process and training for employees for managing hazardous waste operations and emergencies. (OSHA 29 CFR1910.120)

Leak Detection and Repair (LDAR)

A process for finding and repairing leaking equipment so that hazardous emissions are minimized.

material safety data sheet (MSDS)

A document required, by OSHA, to provide information about a chemical product including: name; composition; hazards; first aid; management process for spills; personal protective equipment to be used when handling; safe methods for storing, transporting and disposing; and regulatory requirements.

Occupational Safety and Health Administration (OSHA)

The federal agency within the United States Department of Labor that is responsible for setting standards to promote and enforce employee safety in the workplace.

Process Safety Management (PSM)

The OSHA standard that sets requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals. The PSM consists of 14 elements to improve safety: employee involvement, process safety information, process hazard analysis, operating procedures, training, contractors, pre-startup safety review, mechanical integrity, hot work permit system, management of change, incident investigation, and emergency planning and response. (OSHA 29 CFR1910.119)

Resource Conservation and Recovery Act (RCRA)

The legislation that authorizes the EPA to regulate the management of hazardous and non-hazardous waste, including tracking the substance from generation to disposal, or from “cradle to grave.”

Spill Prevention, Control, and Countermeasure Rule (SPCC)

The legislation that authorizes the EPA to ensure that facilities take steps to prevent oil spills, chemical accidents, and other emergencies, and implement planning and response requirements.

Tennessee Occupational Safety and Health Administration (TOSHA)

The state-level Occupational Safety and Health Administration for the state of Tennessee.

Toxic Substances Control Act (TSCA)

The legislation that authorizes the EPA to require tracking and reporting of new and existing chemicals.

administrative controls

Procedures and methods to reduce exposure to risk factors by altering the way in which work is performed. Examples include safe work permits, training, policies and procedures.

air-purifying respirator

A type of PPE that removes specific contaminants by passing air through a filter.

alarm

An engineering control that warns operators when a process or condition is out of the normal range.

confined space

A potentially hazardous work area that has limited ways to enter and exit, which could make exiting during an emergency difficult.

dilution ventilation

An engineering control that reduces exposure to potentially harmful substances by blowing in clean air and exhausting some “dirty air”. Dilution ventilation is use when air contaminants are of relatively low toxicity, airborne levels are not hazardous, and the dilution air brought in from the outside is not contaminated.

ear muffs

A type of PPE that is designed to protect an operator from noise injuries.

ear plugs

A type of PPE that is Inserted into the ear to protect an operator from noise hazards.

engineering controls

A physical change that reduces hazards by changing the equipment, the process, or the materials used in a process.

face shield

A type of PPE that is designed to protect an operator from injury to the face and eyes.

gloves

A type of PPE that is designed to protect an operator from injuries to the hands.

goggles

A type of PPE that is designed to protect an operator’s eyes from harm.

hard hat

A type of PPE that is designed to protect an operator from head injuries.

hot work

Any work that creates a fire hazard.

industrial hygienist

A professional that monitors the work environment to ensure safety.

isolation

An engineering control that puts a barrier between the employee and a hazard. Examples: machine guards, control room walls, glove boxes

lockout/tagout

An administrative control used to protect employees from the unexpected release of hazardous energy or startup of equipment by isolating the equipment from its energy source and discharging it of remaining energy. The equipment is locked to prevent accidental reconnection to the energy source or tagged to alert of the hazard.

personal protective equipment (PPE)

Clothing or equipment designed to protect all parts of the operator’s body. Examples include hard hats, gloves, respirators, and goggles.

safe work permit

An administrative control that used to ensure that procedures are developed, followed, and documented to control risks related to specific high risk tasks. Examples: lockout/tagout, confined space, and hot work.

self contained breathing apparatus (SCBA)

Air tanks that are part of air-supplying respirators.

ventilation

An engineering control that reduces exposure to potentially harmful substances by containing, controlling, or capturing emissions, at or near their source.

common cause variation

Variation that results from sources that are normal and expected. Variation that is inherent in the process, has little effect on quality, and is predictable over time.

control chart

A graph used to monitor the variability of a process over time and differentiate between natural and special cause variation.

control limits

The “voice of the process.” Indicates the boundaries of normal variation, or the point at which a process is outside statistical control.

Current Good Manufacturing Practice (cGMP)

A set of FDA regulations that ensure that manufacturers minimize chances for contamination, mixups, and errors by using appropriate manufacturing approaches and up-to-date technology and systems.

International Organization for Standardization

An organization composed of national standards institutes from around the world.

ISO 9001

A set of standards for quality management systems.

Joseph Juran

A pioneer of the quality movement who developed the Pareto Principle.

Pareto Principle

A theory that states that 80% of problems are caused by 20% of activities. Used to identify and correct quality problems.

quality

The state of being free from defects, deficiencies, and significant variations in customer or user requirements.

special cause variation

Variations caused by specific (assignable) factors resulting in non-random output.

specification limits

The “voice of the customer.” Indicates the boundaries of the customer requirements for a product.

W. Edwards Deming

An American statistician, educator, and consultant whose advocacy of quality-control methods in industrial production aided Japan’s economic recovery after World War II and spurred the subsequent global success of many Japanese firms in the late 20th century.

Walter Shewhart

A pioneer in the quality movement, known as the Father of Statistical Process Control. Developed the control chart.

piping and instrumentation diagram (P&ID)

A diagram of symbols and direction indicators that describes the components needed to run, monitor and control a process.

title block

Section of a P&ID that contains identification information such as company and process identification, etc.

batch process

A process that has a starting and ending time when the process is finished. In a batch process a “batch” of product completes before another begins.

closed loop control

A method of process control that typically includes a sensor, transmitter, controller and final control device to monitor and adjust a process variable in real time.

continuous process

A manufacturing process in which raw materials are constantly added and product is constantly produced.

open loop control

A method of process control that does not use feedback from a process variable measurement.

parameter

Characteristics of a process that determine the outcome of the product, such as quality, quantity, or duration.

process

The method for turning raw materials into a finished product.

process variable

A condition that can change or affect a process.

set point

The value programmed into controller instruments as the target.

abnormal situation

An event that requires immediate action to prevent serious consequences to people, the environment, the product, or equipment.

potential cause

One of a number of possible events or conditions that interact resulting in an abnormal situation. Identified and evaluated during troubleshooting to determine the probability for being the cause of the abnormal situation.

troubleshooting

A method used to fix a problem when the cause of the problem is not immediately known. A five step process: 1) Recognize the abnormal situation. 2) List and evaluate potential causes. 3) Choose and verify the problem. 4) Correct the problem. 5) Trace the effect of the action.

Learning Aids

Module :

Roles & Responsibilities - Learning Aid

Roles & Responsibilities - Learning Aid document Download

Operator Duties & Responsibilities Flash Cards

Practice Now

Regulatory Issues - Learning Aid

Regulatory Issues - Learning Aid document Download

Regulatory Issues Flash Cards

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Safety On The Job - Learning Aid

Safety On The Job - Learning Aid document Download

Safety on the Job Flash Cards

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Communication - Learning Aid

Communication - Learning Aid document Download

Quality - Learning Aid

Quality - Learning Aid document Download

Quality Flash Cards

Practice Now

P&IDs - ISA Table

ISA table supports content of the P&ID module of the Introduction to Chemical Manufacturing course. Download

P&IDs - Learning Aid

P&IDs - Learning Aid document Download

P&IDs - Sample P&ID

Sample P&ID supports content of the P&ID module of the Introduction to Chemical Manufacturing course. Download

P&IDs Flash Cards

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Process Control - Learning Aid

Process Control - Learning Aid document Download

Process Control Overview Flash Cards

Practice Now

Troubleshooting - Interaction Reference Diagram

Document used as a reference for interactions at the end of the Troubleshooting module within the Introduction to Chemical Manufacturing course. Download

Troubleshooting - Learning Aid

Troubleshooting - Learning Aid document Download

Operator Duties & Responsibilities

Topics

1 . Role of the Chemical Process Operator
2 . The Chemical Manufacturing Facility Part 1
3 . The Chemical Manufacturing Facility Part 2
4 . Batch and Continuous Processes
5 . Shift Work
6 . Working Conditions
7 . Control Room Conditions
8 . Outside Conditions
9 . Expectations Overview
10 . Control Room Expectations
11 . Outside Expectations
12 . Conclusion

Intro to Chemical Manufacturing

Topics

1 . Operator Duties & Responsibilities
2 . Regulatory Issues
3 . Safety on the Job
4 . Communication
5 . Quality
6 . P&IDs
7 . Process Control Overview
8 . Troubleshooting