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Process Safety Information
Introduction to software from EPA's ALOHA, MARPLOT, and CAMEO
for handling ammonia releases.
Describe requirements for Block Flow Diagrams for Process
Safety Management (DFD)
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Describe requirements for Process Flow Diagrams
[Process Safety Management] (PFD)
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Explain requirements for an evaluation of the consequences of
process deviation. [Risk Management Plan]
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Describe the requirements for Piping and Instrument Diagrams
(P&ID)Risk Management Plan & Process Safety Management
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Describe the PSI tracking logs for Process Safety Management
& Risk Management Plan define requirements on materials of construction under
PSM & RMP
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Explain electrical classification requirements List
requirements pertaining to pressure relief systems and safety
relief values (PRV) PSM & RMP
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Give details of required information pertaining to
ventilation systems design under the process safety management
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Explain requirements for design codes and standards under
process safety management & risk management plan describe information required for safety devices (e.g.
interlocks, detection or suppression systems)
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Define Good Engineering Practice documentation compliancy
under risk management plan
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Give details on Refrigerant inventory and calculations
guidelines for RMP
Employee involvement
- List which employees must have PSM awareness training
- Describe employee participation in all PSM activities
- Identify who has access to PSM information
- Explain the procedures involved for any hourly or
salaried employee have serious safety related concerns about any
aspect of the PSM program
- Describe the written plan of action for employee
participation
- Explain document management requirements
- How to communicate concerns
Process Hazard Analysis
- List all appropriate methodologies
- Describe the purpose, objective and scope
- Describe the make-up of the study team
- Teach how to build records for the PHA and to be a PHA
leader
- List reference information required by study team
- List the requirement of a PHA compliance report
- Describe a management system that addresses and resolves
recommendations resulting from the PHA study.
- List required PHA forms
- Explain when a PHA study must be updated
- Operating procedures break down
- list when SOP's need to be revised
- Describe how information from PSI is used during SOP
information
Operating Procedures
- Describe normal SOP's
- Describe start-up SOP's
- Describe emergency SOP's
- Describe SOP's that deal with upset conditions
- Explain what SOP's will be looked at on OSHA's inspection
- Explain involvement of SOP's during MOC implementation
- Describe how SOP's interface with training
Training
- Define and review ammonias MSDS
- List which employees need process training
- Determine the actins and conditions under which the
employee will demonstrate competence or knowledge
- Describe when employers need to evaluate their training
programs
- List or explain required documentations for training
- Explain maintenance and contract worker involvement
- List the PSM elements that process workers must be
trained in
- List minimum supervisor personnel
Contactors
- Explain contractor selection recommendations
- List what is required for
contractor pre-bid awareness
- List what is required for
contractor post-bid awareness
- Specify contractor responsibilities
- Explain contractor performance
follow-up
- List documentation requirements
- Describe contractor employee sick
and injury log responsibilities
- Explain the use of a work
authorization system
Pre-Startup Safety Review
- List the procedures for new
facilities
- List the procedures for modified
facilities
- Explain the necessity of a pre-starup
safety review verification form
- State who has the responsibility
for the completion of a pre-startup safety review
Mechanical Integrity
- Define IOM's
- List components that should be
included in the inventory
- Explain ;the need for owner
generated IOM's
- Define a "maintenance program
requirements"
- List and explain the documents
required for an inspection and testing program
- Explain the course of action
required when deficiencies found during and inspection are outside
acceptable limits
- List the schedules, inspection
forms and log sheets that are to be included as part of the
training materials
- Explain the requirements of quality
assurance program
Hot Work
- Explain the purpose of hot work
permits
- Identify the situations when a
"fire watch" is required
- Define a hazardous location
- Define a hot work operation
- List the responsibilities of the
hot work permit originator
- Lit the responsibilities of the
site maintenance supervisor
Management of Change
- Explain the purpose of MOC
- Ste the provisions to be considered
for temporary change
- Define and give example of change
in equipment that requires MOC
- Define and give examples of changes
in procedures when need
- Define and give examples of change
in process technology
- Define and give example of a major
change
- Define and give example of a minor
change
- Define and give examples of
"replacement in kind"
- Describe and list the procedures
required for initiating and completing a MOC
Incident Investigation
- Describe the purpose of incident
investigation
- List the circumstances or
occurrences, which require formal incident investigation
- List the major investigation
procedures that should be followed
- Explain the list the
responsibilities of the incident investigation team
- Explain the contents of an "Incident
Summary" form
- Explain the contents of an
"Incident Description" form
- Explain the contents of an
"Approvals, Follow-up and Review" form
- Explain the contents of a
"Close-out" form
Emergency Planning and Response
- Define an emergency action plan
- Define an emergency response plan
- Describe a Minimum emergency response plan
- Describe procedures for handling small releases
- List the three levels of emergency response
- List procedures for emergency evacuation
- List requirements of alarm systems
- List training requirements
Compliance Audit
- List the PSM elements that must be audited
- List the frequency that audits must be conducted
- List the minimum contents of a final report of an audit
- Explain and list the Compliant Audit reports that must be
retained by the facility
- List factors that may increase the frequency of
compliance audits
- Explain audit certification
- List Compliance Audit documentation
- Define the guidelines for an audit team
Trade Secrets
- State the purpose of the "Trade Secrets"
element
- List the employer's responsibility towards those persons
responsible for compiling PSI, SOP's, incident investigation,
emergency planning and response, and compliance audits
Risk Management Plans (RMP)
- List the three program levels
- Define stationary source, Process, Threshold Quantity,
Vessel, Public Receptor, and Environmental receptor
- Work with and explain why it important to work with their
LEPC Define their job functions
- Describe off site accident analysis
- Describe worst-case scenario
- Work with five-year accident history reports
- Describe alternate scenario
Kansas Competency Skills
- Work with oral instructions
- Participate in-group communication activities
- Compile and maintain records of course
- Build group consensus
- Learn how to research regulations in the CFR 29 or CFR 40
- How to handle an OSHA & EPA audit
- Reporting ammonia release correctly
- How to certify your refrigeration operators in-house
- Each Student will receive a compliance audit for PSM/RMP
to evaluate his or her own plant
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