Training Requirements: Process Overview (Part 3 of 4)

The first article in this four-part series on training provided an overview of RMP/PSM/CalARP training requirements. While the second article covered training requirements for general facility employees, this article will explain what it means for operators to be trained on an overview of the process.

Facilities needing to adhere to RMP/PSM regulations have spent thousands or even millions of dollars on the process containing a hazardous chemical. A brand new ammonia refrigeration system can easily cost over a million dollars. Presidents and executives of these companies see the value of installing high quality equipment, but have been known to scoff at “wasting” a day’s work on training operators. This is much like buying a nice 72” HD television, but only watching VHS tapes: there is an unknown amount of wasted potential. Sadly, the metaphor is not severe enough. While watching a VHS on a nice TV might be annoying, it is not going to put anyone in danger. Failing to train operators on how to understand and operate the system is a huge liability. As mentioned in the first article in this series, human error accounts for the majority of releases of ammonia. This article will explain the two types of training required for operators.

Operators are required to be trained on an overview of the process. You might be wondering what that means. Essentially, operators need to know how your process works. If your process is an ammonia refrigeration system, operators need to know how the refrigeration cycle works. Unlike training requirements for general facility employees, training for operators is on a sliding scale depending on what is required of the employee. Operators who are only monitoring the system and reporting problems to contractors may only need to be trained on the Block Flow Diagram/Process Flow Diagram for your process. Understanding how a system works and how your specific process works is the base level for process overview training.

After operators comprehend the basic system components, they may also require training on the Piping & Instrumentation Diagrams (P&IDs) and Safety Systems for the process. A key indicator that an operator understands the process is if they are well versed in the Process Safety Information.

Beyond understanding your specific process, it is oftentimes helpful to take advantage of outsourced training from industry experts. If your area provides them, Chemical Safety Days are a great resource for helping your operator have a better understanding of a process. Contractors in your industry may also provide similar training. If feasible, the best option for training employees on an overview of the process is sending them to industry-specific training programs or certificate courses. For example, an ammonia refrigeration operators may be able to attend a week-long, hands-on class which will prepare them to become certified by RETA.

In summary, those operating the process need to understand how the process works. For many facilities, training your operators on a Block Flow Diagram will be sufficient. For increased understanding of the process, operators should study the other elements of the Process Safety Information. Outsourced, industry-specific training courses or certificates is oftentimes the highest level of process overview training. Read Part 4.