Process Equipment and Operations

Duration: 0.50 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Equipment rarely fails without first sending signals. The question is, are you looking for the signals? Utilizing an oil analysis program is one of the best ways to find those early indications of equipment failure. This interactive online course will teach you about the importance of instituting an oil analysis program and partnering with the right laboratory. You will also learn how to choose what equipment to sample, what tests to use and how to train your personnel.

Learning Objectives

By the end of this course, you will be able to:

• Recognize the difference between basic oil analysis and an oil analysis program
• Describe how to select equipment for sampling
• Describe how to select a laboratory Identify different types of oil analysis tests
• Describe best practices for training personnel to obtain samples from equipment

Duration: 2.00 Hrs

Course Level: Fundamental
Languages: English
Capability: Audio, Video, MobileReady

Pumping stations are necessary where large amounts of water must be transported through a piped distribution system. Knowing the characteristics of piping and valve materials will allow you to optimize the hydraulic design of your pumping stations. This interactive online course will teach you about the different water distribution station pump classifications. You will also learn about pump designs and motor types. Additionally, you will learn about the electrical systems of pumping stations.

Learning Objectives

By the end of this course, you will be able to:

• Identify types of pumps utilized in pumping stations based on their mechanical configuration classification
• Identify the basic steps required for sizing pumps and motors to transmit and distribute safe and sustainable water
• Identify the types of engines that are in use for pumping stations and describe their benefits for critical operations so as not to affect the environment and public health in an adverse manner
• Describe key electrical fundamentals involved in pumping station design, including grounding, over current protection, and branch circuiting

Duration: 0.50 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, MobileReady

Many industrial processes must heat or cool fluids to produce products. Heating and cooling are often accomplished by transferring heat between fluids, and this heat transfer between fluids occurs in heat exchangers. There are many types of heat exchangers, but one of the most common types is a shell and tube heat exchanger. In this interactive, online course, you will look at the operation of a typical shell and tube heat exchanger, including startup and shutdown. You will also explore some of the problems associated with the operation of a typical shell and tube heat exchanger.

Learning Objectives

By the end of this course, you will be able to:

• Describe a general procedure for starting up a shell and tube heat exchanger
• Describe a general procedure for shutting down a shell and tube heat exchanger
• Describe general operator responsibilities associated with the operation of a shell and tube heat exchanger
• Explain the causes and effects of fouling, tube leaks and trapped gases
• Describe the symptoms of fouling, tube leaks and trapped gases and how to reduce their occurrence

Duration: 0.50 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, MobileReady

In many industrial facilities, various pieces of equipment and fluids used in process systems need to be cooled. Disposing of or discharging hot water into lakes or rivers can lead to thermal pollution, and water that is discharged must be replaced. For these reasons, it’s often more efficient to cool the hot water with a cooling tower and reuse it. This interactive online course will introduce you to cooling tower systems and a couple of types of cooling towers, and you will see how a typical cooling tower is operated. You will also look at how chemistry is involved with maintaining a cooling tower.

Learning Objectives

By the end of this course, you will be able to:

• Describe the operation of a basic cooling water system and what occurs in the tower during the cooling process
• Explain the general operation of a natural-draft cooling tower and the two types of mechanical-draft cooling towers: induced-draft towers and forced-draft towers
• Describe a typical shutdown and startup procedure for one cell of a multicell cooling tower
• Cite examples of typical operator checks for cooling towers
• Explain what suspended and dissolved solids are, how they affect a cooling water system, and how problems caused by suspended and dissolved solids can be minimized
• Explain what dissolved gases and microorganisms are, how they affect cooling water systems, and how their effects can be minimized
• Describe ways chemicals are added to cooling water systems and precautions when working with hazardous chemicals

Duration: 0.50 Hrs

Course Level: Intermediate
Languages: English
Capability: Audio, MobileReady

The primary responsibility of a plant operator is to ensure that a unit functions safely and efficiently. To fulfill that responsibility an operator must be able to perform different types of duties under a variety of operating conditions. In this interactive online course, we’ll focus on operator responsibilities related to plant production and we’ll examine some safety responsibilities and regulations that apply to various operating conditions. We’ll also examine some safety permits and regulations that operators must be familiar with.

Learning Objectives

By the end of this course, you will be able to:

• Describe operator responsibilities associated with routine production duties, data interpretation, waste disposal and vapor emissions monitoring
• Describe operator responsibilities associated with preventative maintenance and troubleshooting
• Describe operator safety responsibilities associated with normal plant conditions, startups and shutdowns
• Describe the operator’s role in lockout/tagout procedures and confined space procedures
• Describe the purpose of the following regulations: HAZCOM, HAZWOPER, SARA III
• Describe the basic guidelines for effective operator communication and interaction with others inside and outside the plant

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, MobileReady

When you’re working around reactors, your primary responsibility is to make sure that the chemical reactions occur safely and efficiently. In a very real sense, you’re responsible for controlling what goes on inside the reactors. In order to do that, you need to know some basic principles that govern reactor operations. Then, you can apply these principles to any reactor in your plant. This interactive online course focuses on the fundamentals of reactors used in process plants. Specific areas covered include the basic components of a reactor, reactor operation, types of reactors, auxiliary equipment associated with reactors, and the operator’s role in reactor operations.

Learning Objectives

By the end of this course, you will be able to:

• Describe the conditions that affect chemical reactions in a chemical reactor and why it is important to charge a reactor correctly
• Define endothermic and exothermic chemical reactions
• Cite examples of basic reactor components and commonly associated auxiliary equipment
• Explain how to identify batch and continuous stirred tank reactors
• Describe the general operation of the following reactors: batch stirred tank, continuous stirred tank, fixed-bed, and fluidized, moving-bed
• Discuss general operator responsibilities associated with reactor system operation

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

The purpose of this course is to introduce participants to the principles of evaporation and the purpose of evaporation in process systems. The focus of the course is on the advantages and applications of various types of evaporators used in industry and on standard operator duties. This course consists of a streaming video course. It may also contain links to various Internet sites, and course reference material in a PDF format.

Learning Objectives

Principles of Evaporation

• Describe the basic principles of evaporation.
• Describe some of the process variables that can affect the operation of evaporator systems.

Batch and Continuous Evaporator Systems

• Describe the components and operation of a batch evaporator system.
• Describe the components and operation of a continuous evaporator system.
• Describe how liquid level can affect evaporator system operation. Film Evaporator Systems
• Describe the components and operation of a rising film evaporator, a falling film evaporator, a wiped film evaporator, and a multiple-effect evaporator.
• Describe the components and operation of a plate evaporator.

Evaporator Auxiliaries

• Describe how auxiliary devices and systems such as condensers, air removal systems, pumps, valves, storage tanks, purging systems, heat exchangers, and centrifuges are used in evaporator systems. Evaporator System Startup
• Describe general startup procedures for a typical evaporator system. Evaporator System Operation and Shutdown
• Describe general operator responsibilities during evaporator system operation.
• Describe general shutdown procedures for an evaporator system.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Process facilities contain a number of process units, and each process unit consists of one or more process systems. These process systems are made up of many different types of components, including various types of process vessels. A process operator must be familiar with the functions and features of all the different types of process vessels. This course focuses on a general group of vessels that can be referred to as auxiliary vessels.

Learning Objectives

Topic I: The Process System

• Identify the major parts of a process system.
• Define the terms primary vessel and auxiliary vessel.
• List three major functions of auxiliary vessels.

Topic II: Storage Vessels 

• Describe common types of auxiliary vessels that store bulk solids.
• Describe general types of aboveground storage tanks that store bulk liquids.
• Describe a common type of auxiliary vessel that stores gases.

Topic III: Mixing Vessels

• Define the terms homogeneous mixture and heterogeneous mixture.
• Describe the basic parts and operation of a typical mixer.
• Describe the two main types of impellers used for mixing low-viscosity liquids and explain how the positioning of an impeller can affect mixing.
• Describe various types of impellers used for mixing high-viscosity liquids.
• Describe the operation of a high-speed mixer.
• Describe the operation of a jet mixer.

Topic IV: Basic Separation Vessels

• Define the following terms: density, backwashing, immiscible, and interface.
• Describe how the use of separation techniques in auxiliary vessels is different from the use of separation techniques in primary vessels.
• Describe the following types of auxiliary separation vessels: settling tanks, or separators; knockout drums; filters; and decanters.

Topic V: Centrifuges and Cyclones

• Describe the basic operation of a basket centrifuge.
• Describe the basic operation of a solid-bowl centrifuge.
• Describe the basic operation of a disc centrifuge.
• Describe the basic operation of a cyclone.

Topic VI: Clarifiers, Absorbers, and Adsorbers

• Describe the basic operation of a clarifier.
• Describe the basic operation of a scrubber or an absorber.
• Describe the basic operation of an adsorber.

Topic VII: Strippers and Evaporators

• Describe the basic operation of a stripper.
• Describe the basic operation of a continuous circulation evaporator.

Topic VIII: Dryers

• Describe the basic operation of a tray dryer, a pressure filter dryer, a drum dryer, a paddle-type dryer, and a double cone dryer.
• Describe the basic operation of a desiccant dryer.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

In this course, you will learn that centrifugation is a mechanical means of separating materials of different densities by spinning them. You will also learn about the types of centrifuges, their auxiliary equipment, and their basic operating procedures.

Learning Objectives

In this course, you will learn to:

• Discuss centrifugation
• Review types of centrifuges and auxiliary equipment
• Describe typical startup and shutdown procedures
• Explain general operator responsibilities

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

The purpose of this course is to provide participants with a basic understanding of the operation of drum, paddle-type, and freeze-drying operations.

Learning Objectives

• Define two process variables that must be controlled in most dryers.
• Describe operation of the tray dryer controls.
• Describe typical operation of a circular tray dryer.
• Describe typical operation of a drum dryer.
• Review steps an operator follows to start a paddle-type dryer.
• Explain how the freeze-drying process works.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This course focuses on the separation of mixtures by means of filtration and screening. The operation of devices used to accomplish filtration and screening are covered along with the operator’s role and screening unit operations.

Learning Objectives

• Describe the basic principles of screening and filtering.
• Identify screen types, functions, and operation.
• Describe cartridge filter operation.
• Describe gravity and pressure filters.
• Describe vacuum drum filter operation.
• Describe pre-coat filter operation.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Industrial process operations produce many different types of useful products. In many cases, however, these operations also produce waste materials that must either be recovered for reuse or safely discarded. Although waste materials may be solids, liquids, or gases, this course focuses on waste gases. Specific attention is directed to how waste gases are removed from process systems and safely disposed of.

Learning Objectives

Topic I: General Considerations

• Describe some considerations for handling waste gases.
• Explain how a relief system can remove waste gas.

Topic II: Venting

• Describe conditions that require venting.
• Describe various types of vents.
• Describe work practices that help ensure the safe venting of equipment and vessels.

Topic III: Purging

• Explain why nitrogen and fuel gas are used for purging.
• Describe two methods used to purge vessels and equipment.
• Explain what inerting is and why and how it is done.
• Describe safety concerns and operator responsibilities associated with purging.

Topic IV: Flare System

• Describe safety considerations associated with flaring.
• Describe the main components and the basic operation of a flare.

Topic V: Flare Operations

• Describe typical operator responsibilities associated with a flare system startup.
• Describe some typical control room operator responsibilities associated with normal flare operation.
• Describe typical outside operator responsibilities associated with normal flare operation.
• Identify some abnormal flare operating conditions and describe typical operator responsibilities for handling them.
• Describe basic operator responsibilities associated with a flare shutdown.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Every day large quantities of liquid products are transported in and out of industrial facilities. These products are generally carried by tank trucks, tank cars, or barges. This course discusses how loading, unloading, and other transfers of bulk liquids must always be done safely and efficiently.

Learning Objectives

• General procedures and safety concerns
• Tank truck features and associated equipment
• Loading tank trucks
• Unloading tank trucks
• Loading tank cars
• Unloading tank cars
• Unloading barges

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

This training program focuses on common types of portable and emergency equipment that are found in industrial facilities. Some types of portable equipment are used to periodically analyze conditions in a process or inside process equipment. Other types of portable equipment, such as pumps, have specialized roles that are determined by plant procedures and policies. Emergency equipment, such as respirators and fire fighting equipment, is used strictly during emergencies.

Learning Objectives

Topic I: Oxygen Analyzers

• Describe the purpose of an analyzer.
• Explain how to calibrate and use a typical oxygen analyzer.

Topic II: Combustibles and Hazardous Gas Analyzers

• Explain how to calibrate, set up, and interpret a reading from a combustible analyzer.
• Explain how to set up and use a hazardous gas analyzer.

Topic III: pH, Temperature, and Vibration Analyzers

• Explain how to calibrate and use a pH analyzer.
• Explain how to calibrate and use a thermocouple thermometer.
• Explain how to use a vibration meter.

Topic IV: Portable Process Equipment After completing this lesson, you should be able to:

• Explain how to use a hand-operated drum pump.
• Explain how to use an air-operated drum pump.
• Explain the basic operations of a portable centrifuge.

Topic V: Respirators

• Describe general conditions that require the use of respiratory protection.
• Explain how a fit check is performed on a typical cartridge-type air purifying respirator and how a cartridge is selected.
• Explain how a typical air-supplied respirator is put on.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video, MobileReady

Equipment such as pumps, compressors, and fans is essential to the operation of an industrial facility. Before this equipment can operate, however, it must be supplied with power. Although electric motors are among the most common means of supplying the power necessary to drive equipment, other drivers, such as internal combustion engines, gas turbines, and steam turbines, are also used. This program focuses on steam turbines.

Learning Objectives

Principles of Operation

In this topic, you will learn to:

• State the function of a steam turbine.
• Define the term “impulse movement.”
• Describe the operation of blading in a typical single-stage steam turbine.

Auxiliary Devices and Systems

In this topic, you will learn to:

• Identify typical steam turbine auxiliary devices and state the function of each device.
• Describe two types of turbine auxiliary systems and explain what each is used for.
• Describe how speed is controlled in a typical single-stage steam turbine.
• Explain what an overspeed trip mechanism is and describe its general operation.

Turbine Components

In this topic, you will learn to:

• Identify the main parts of a typical single-stage steam turbine and state the function of each part.

Turbine Startup, Operation, and Shutdown

In this topic, you will learn to:

• Describe a general procedure associated with the startup of a typical non-condensing, single-stage steam turbine.
• Describe some of the general checks commonly made on a non-condensing, single-stage steam turbine during operation.
• Identify the basic steps associated with normal and emergency shutdowns of a typical non-condensing, single-stage steam turbine and related equipment.

Typical Operating Problems

In this topic, you will learn to:

• Identify some common operating problems for a noncondensing, single-stage steam turbine and explain how they can be corrected.

Duration: 1.00 Hr

Course Level: Intermediate
Languages: English
Capability: Audio, Video

Many raw materials and finished products in chemical plants are dried at some stage of processing. This training module will cover the basic principles of drying and how drying is accomplished in different kinds of dryers commonly used in chemical plants.

Learning Objectives

• Describe drying and ways the drying process is accomplished.
• Identify reasons for drying chemical products.
• Identify two methods of heat transfer.
• Examine two basic types of dryer classifications.
• Discuss common types of dryers.