Chemical Operator III

Anonymous

North Carolina (SAA)

Documents

Individual state requirements may vary. Please contact your local apprenticeship office to ensure this version is suitable to your state’s requirements.

Work Process Schedule

Work Process Content

On the Job Training

Anonymous

108

Skills

Controlling/Operating Chemical Processes/Equipment

Perform technical mathematical calculations
Perform addition, subtraction, multiplication and division of whole numbers, fractions, and decimals with or without a calculator
Convert to metric, decimal, or fractional measurements
Identify, describe and use measuring tools
Learn and understand the terms flow, volume, weight, mass and the unit typical for operation
Read, follow and sign: all SOPS, handbooks and other manual for the operation of chemical process equipment needed

Waste Water System

Boiler and related equipment (operation, daily maintenance, safety checks)
Boiler Testing Excel log: monitoring boiler test results
Boiler hard copy log book daily entries: recording observations
Filter press (operation, daily maintenance, safety checks)
Paint filter testing Excel Log: Tracking testing performed and logging pictures taken
Report form for paint filter testing, manifests for can disposal: regulatory testing and paperwork for removal company
Treat with supervision waste water tanks
Maintain wastewater Excel log: combined data wastewater an lab test results
Daily hard copy log of tanks treated, presses dumped, dip made etc: tracking work performed for daily reports
Treat without supervision waste water tanks
Initiate and proceed retreat of waste water tanks
Release passed waste water tanks
Mixing Tank (operation, daily maintenance, safety checks)
Understand and be capable of sketching waste water way in facility (TEST)

Chemical Storage System

Assist loading of storage tanks
Supervise loading of storage tanks
Know MSDS for chemicals (TEST)
Understand and be capable of sketching bulk storage area (TEST)
Understand and sign SOP to store drums and IBCs (totes)

Production Tanks

Operate production tanks (floor and PLC)
Interpret and plan job processes from chemical engineering "recipes"
Control process tanks and suggest corrective actions required
Pre-drying oven (operation, daily maintenance, safety checks)
Calcination oven (operation, daily maintenance, safety checks)
Compressed Air (operation, daily maintenance, safety checks)
Flipping and Washing tables (operation, daily maintenance, safety checks)
Ventilation (operation, daily maintenance, safety checks)
RO-Skid (operation, daily maintenance, safety checks)
Ventilation (operation, daily maintenance, safety checks)
Ultrasounds (operation, daily maintenance, safety checks)
Cranes (operation, daily maintenance, safety checks)
Understand waterways of production
Test product samples for chemical characteristics, pH levels, concentrations and maintain data
Understand function of valves, pumps, overflows, etc. around the production and waste water

Regeneration Lab

Monthly Hood performance check excel log: monitoring hood performance
Laboratory Instrument Inventory Excel log: tracking calibration dates, consumables
Instrument calibration log, hard copy: record calibration testing
Laboratory Chemical Inventory Excel Log: tracking lab chemical inventory
Monthly eyewash Check Excel log: tracking eyewash/shower performance checks

Handling, Moving Objects, Mechanical Devices

Learn proper technique to dry clean plate catalyst
Learn proper technique to dry clean honey comb and corrugated catalyst
Learn proper technique to air blow, needle scale, pressure was catalyst
Learn proper technique to handle wet catalyst in production, flipping table, forklift, etc
Complete rigging class in house
Complete in-house forklift driver training
Demonstrate ability to use basic power tools
Demonstrate proper care of hand power tools (grinder, drills, etc.)
Perform safety and house keeping tasks
Follow OSHA, EPA, and MSDS requirements
Identify safety rules and regulations
Carry out assignments while adhering to safety and OSHA guidelines
Read and interpret MSDS sheets and handle hazardous materials accordingly
Explain the causes of fires and methods of preventing and extinguishing
Flipping and Washing tables (operation, daily maintenance, safety checks)
Ventilation (operation, daily maintenance, safety checks)

Operating Laboratory Equipment

Learn proper technique to weigh and transfer wet and dry chemicals
Demonstrate understanding of dilution factors and the appropriate use in calculations
Learn proper technique to titrate for quantization
Learn proper techniques to dispose of chemicals
Perform filter press cake Paint Filter testing
Perform wastewater testing
Perform instrument calibrations and checks (balances, pH meters, conductivity meters, etc)
Perform RO Skid testing
Demonstrate understand of how to perform a trial regeneration
Perform boiler testing
Demonstrate ability to identify basic glassware
Demonstrate ability to use balance, meters, and other lab instruments
Demonstrate proper use of test kits and strips
Perform safety and house keeping tasks
Follow OSHA, EPA, and MSDS requirements
Identify safety rules and regulations in the laboratory
Carry out assignments while adhering to safety and OSHA guidelines
Read and interpret MSDS sheets and handle hazardous materials accordingly
Keep duty station clean and safe for work
Perform chemical mathematics calculations
Convert to metric, decimal, or fractional measurements for length, volume, flow, mass
Identify, describe and use measuring instruments in the Laboratory
Identify, label, and care for measuring instruments such as: pH meters, conductivity meters, balances, calipers

Quality Control

Catalyst Receiving inspection SOP
Inventory Catalyst Regeneration SOP
Process Control and Quality Control SOP
Catalyst Storage SOP
Demonstration of comprehension of where samples are taken, how to take them, why to take them
Module and Catalyst Inspection Inbound SOP
QA/QC Manual

QA/Monitor Surroundings/Gathering Information/Solving Problems/Identifying Objects

Apply proper technique to sort catalyst (dirty clean) by predefined criteria
Apply proper technique to repack modules
Read Module and Catalyst Inspection Outbound SOP
Learn Final inspection of a honeycomb job
Final inspection of a honeycomb job without supervision
Learn Final inspection of a plate job
Final inspection of a plate job without supervision
Learn and utilize the QA-database Module Management system
Learn how you react on alarms from PLC and pass the written test
Do daily workarounds for 30 days of each of your areas before start working to determine potential issues and keep records
Prepare observation checklists for following equipment (dryer, oven, boiler, production tanks, cranes, catalyst modules)

Communication/Record Keeping/Documenting Information

Write one handbook for a piece of equipment chosen by the Mentor
Keep personal log book on weekly base to record learning efforts and maintaining Laboratory data
Read and understand SOPs (written test for 5 of them)
Presentation I infront of senior staff member (after 1 year) (teamwork)
Presentation II infront of senior staff member (after 2 years) (decision making based on real case)
Presentation III infront of senior staff member (after 3 years) (experience in the past 3 years)

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