Basic Plant Operations Training Instructor Guide TABLE OF CONTENTS

Size: px

Start display at page:

Download "Basic Plant Operations Training Instructor Guide TABLE OF CONTENTS"

Darlene Jefferson
5 years ago
Views:

Basic Plant Operations Training Instructor Guide TABLE OF CONTENTS Suggestions for Teaching Basic Plant Operations...2 Overview of Modules and Lessons.

1 Basic Plant Operations Training Instructor Guide TABLE OF CONTENTS Suggestions for Teaching Basic Plant Operations...2 Overview of Modules and Lessons...2 Suggestions for Teaching Specific Topics...4 End of Module Quizzes Answer Key...5 End of Module Quizzes Answer Key (continued)...7 Instructor Notes for Case Studies...8 Plant Operations Pre-Certification Answers... 11

2 Suggestions for Teaching Basic Plant Operations Basic Plant Operations has been designed include all of the tasks, decisions, and safety considerations required for bulk plant personnel inside the plant fence. The CETP certification exam offered by NPGA covers the entire contents of this course and those wishing to take the exam should complete the course in its entirety. In some cases, instructors or plant management may wish to use only a portion of the course for safety meetings or refresher training. With this in mind, the tables below provides an overview of the lessons included in each module followed by suggestions for using pieces of the course to teach specific topics. Overview of Modules and Lessons Module # Module Title Topics 1 Identify the Main Components of a Bulk Plant 1. Receiving, Storage and Container Filling Systems 2. Hazards and Precautions 3. Propane Containers 2 Operate the Propane Liquid Supply System 1. Open the Liquid Supply Line 2. How an Excess Flow Valve Works in a Liquid Line 3. Detecting Contamination in Stored Propane 4. Operate with Multiple Storage Tanks of Different Diameters 3 Inspect and Fill DOT Cylinders 1. Identify DOT Cylinders 2. Inspect DOT Cylinders Before Filling 3. Fill a DOT Cylinder by Weight 4. Fill a DOT Cylinder by Volume 5. Observe Safety Precautions While Filling Containers 6. Inspect and Fill a Composite Cylinder 4 Inspect and Fill Vehicle- Mounted ASME Tanks 1. Inspect an ASME Tank Before Filling 2. Fill a Vehicle-Mounted ASME Tank 3. Recover from a Breakaway 5 Requalify DOT Cylinders by Visual Inspection 1. DOT Requalification Requirements 2. Requalification Process Overview 3. Prepare for Requalification 4. Perform an Inspection on a Steel Cylinder 5. Test for Leaks 6. Process the Cylinder 7. Special Requalification Considerations for Certain Cylinder Materials and Types 8. Module Summary 2

3 Module # Module Title Topics 6 Maintain Cylinders and ASME Tanks 7 Unload a Cargo Tank Motor Vehicle (CTMV) 8 Maintain Bulk Plant Systems and Equipment 9 Bulk Plant Tasks Requiring Additional Training 1. Prepare New Cylinders Received at the Bulk Plant 2. Methods for Removing Propane from a Container 3. Evacuate DOT Cylinders 4. Prepare ASME Tanks for Installation 5. Evacuate ASME Tanks and the Bulk Plant 6. Repair and Replace Container Valves 7. Inject Methanol 8. Flare Propane Vapor From Containers 9. Auto-Refrigeration 10. Apply Protective Coatings to Propane Storage Containers 11. Recognize Anhydrous Ammonia Contamination 1. Characteristics of Bulkheads and Plant Piping 2. Characteristics of CTMVs 3. Hazards and Precautions 4. Measure the Liquid Level in a Tank 5. Determine the Amount of Propane to be Unloaded 6. Unload a Bobtail Using the Bobtail Pump 7. Safely Disconnect the Bobtail Liquid Hose 8. Empty the Bobtail Liquid Hose 9. Unload a Cargo Transport Using the Transport Pump 10. Safely Disconnection the Transport Liquid Hose 1. Observe Safety Precautions when Performing Maintenance Activities 2. Inspect and Maintain Bulk Plant Systems and Equipment 3. Follow and Maintain Bulk Plant Procedures 1. Bulk Plant Tasks Requiring Additional Training 3

4 Suggestions for Teaching Specific Topics If you want, teach Use Notes An overview of bulk plant Modules 1 and 2, all lessons equipment and how to use the liquid supply system. Identifying DOT cylinders. Module 3, Lesson 1 Filling a DOT cylinder by weight. Module 3, Lessons 2, 3 and 5 Filling a DOT cylinder by volume. Module 3, Lessons 2, 4 and 5 Before teaching this topic, make sure that this procedure is permissible in your area. Filling a composite cylinder Module 3, Lessons 5 and 6 Filling a vehicle-mounted ASME Module 4, all lessons tank Requalify DOT cylinders by visual inspection Module 5, all lessons This module is specifically designed to be taught either with the course in its entirety or as a stand-alone course. Glossary terms and other reference material have been included in the body of the module content. Preparing new DOT cylinders and Module 6, Lessons 1 and 4 ASME tanks for service Methods for removing propane Module 6, Lessons 2, 3, 5 and 8 from containers Injecting Methanol Module 6, Lesson 7 Applying protective coatings to Module 6, Lesson 10 propane storage containers Recognizing anhydrous ammonia Module 6, Lesson 11 contamination Auto-Refrigeration Module 6, Lesson 9 and Module 7, Lesson 7, 8 and 10 Unloading Equipment and Module 7, Lessons 1 through 5 Systems Unloading a Bobtail Module 7, Lessons 5 through 8 Unload a CTMV Module 7, Lessons 5, 9 and 10 Maintaining bulk plant equipment and systems Module 8, all lessons 4

5 End of Module Quizzes Answer Key Module 1 Module 2 Module 3 Module 4 1. C 2. D 3. A 4. C 5. B 6. B 7. A 8. C 9. C 10. C 11. A MOD 3, question 7 answer 1. D 3. D 4. C 5. B 6. D 7. C 8. C 9. A 10. D 11. C 12. D 13. A 1. D 3. B 4. C 5. C 6. A 7. see below 8. see page 5 9. see page B 11. B C 14. D 15. D 16. D 17. B 18. C 19. D 20. C 21. C D 24. D 25. C 26. C 27. D 1. B 3. B 4. B 5. B 6. B 7. B 8. A 9. D 5

6 MOD 3, question 8 answer MOD 3, question 9 answer 6

7 End of Module Quizzes Answer Key (continued) Module 5 Module 6 Module 7 Module 8 1. A 2. C 3. C 4. B 5. A 6. C 7. Dent D, F Attachment Bulge E Fire Damage B, G Corrosion C Valve Damage A 8. C 9. B 10. A 11. B 12. D 13. A 14. C 15. C 16. A 17. A 18. B 19. B 20. C 21. B B 24. B 25. D 1. B 2. A 3. B 4. D 5. A 6. C 7. B 8. D 9. B 10. B 11. B 12. D 13. D 14. B 15. A 16. B 17. B 18. C 19. D 20. C 21. D A 24. B 25. C 26. D 27. A 1. B 3. C 4. C 5. A 6. C 7. 25,000 gallons gallons 9. B 10. B 11. B 12. A 1. B 3. B 4. D 5. B 7

8 Instructor Notes for Case Studies Module 2, Lesson 5 Securing the Liquid Supply System Case Study With Bob gone and the driver in the diner across the street, the plant will be unattended. Bob is obligated to shut down the liquid supply and lock the gate before leaving. If the driver is authorized to open the gate, he should have his own key. If not so authorized, he must exit the plant with the truck before Bob locks the gate. Module 3, Lesson 2 Inspecting Portable Cylinders, Case Study #2 Deterioration of valve body and threads may allow valve to leak or to be expelled from the opening. Module 3, Lesson 4 Filling by Volume, Case Study The cylinder is probably overfilled. If the cylinder warms up, it may unexpectedly release propane through the pressure relief valve while in transit or in use. Remedy: Either weigh the cylinder or use FMLLG to check for overfill. Bleed off excess, and verify using either of the above methods. Module 3, Lesson 5 Safety Precautions, Case Study #1 Static charge can build up on the plastic crate. Module 3, Lesson 5 Safety Precautions, Case Study #2 What should Daisy do? Stop filling immediately. Ask the customer to move away from dock and return to safe area. Explain danger of static discharge resulting from jacket rubbing on other fabric. What company policy is probably being ignored? Keep visitors away from transfer locations. 8

9 Module 3, Lesson 5 Safety Precautions, Case Study #3 Where should the pallets should be placed? At least 25 feet from the transfer location. Stretch wrap poses a threat of static discharge. What precautions must Bill take when unwrapping the new cylinders? Place plastic film in trash disposal container at least 25 feet from transfer location. What precautions should Bill take when moving from the unwrapping task to the filling task? Unless working on a grounded floor mat, find a way to discharge to ground to get rid of any static charge on Bill. Module 3, Lesson 5 Safety Precautions, Case Study #4 What should Don do? Stop filling immediately. Assume that NO SMOKING sign is posted on fence. Inform the customer that he/she must move 25 feet away from the transfer location before lighting up. Module 3, Lesson 5 Safety Precautions, Case Study #5 What kind of problem do we have here? Stuff on the floor constitutes a safety hazard. Either Ben or George could trip or slip. What could you advise Ben to do: Ben must clean up the area. Has solid ground for doing so, His own safety is at risk. Company policy is on his side. Ben's problem is the mess, not George. Ben should avoid argument with George. Module 3, Lesson 5 Safety Precautions, Case Study #6 If you were in Steve s shoes, what would you do? Steve could slip, and is therefore at personal risk. Company policy is on his side. Explain the risk to Dave. If Dave won't clean it up, Steve should do so. 9

10 Module 4 Case Study What kind if risk is Willie taking by not verifying that the pilots are out and electronic ignition systems are disabled? In the event of a propane leak, propane vapor can be drawn into the air intake. If the electronic ignition is not disabled on the heater, and the thermostat calls for heat (remember, it's cool outside), a fire or explosion can result. Module 7 Case Study What kind of risk is the drive running? Dragging the valve may cause the handle to turn and the valve to open, releasing liquid propane. If you were Mike, what would you do? Tell the drive to stop. Explain the risk. Demonstrate the proper method grab the valve by the body. 10

11 Plant Operations Pre-Certification Answers 1. A 3. A 4. B 5. C 6. A 7. D 8. C 9. D 10. D 11. C 12. A 13. B 14. B 15. B 16. D 17. C 18. D 19. C 20. D 21. B 22. D 23. B 24. B 25. B 26. B 27. C 28. C 29. B 30. A 31. C D 34. A 35. B 36. B 37. A 38. D 39. A 40. B 41. B 42. A 43. C 44. B 45. C 46. B 47. C 48. A 49. B 50. B 11

5.1 Design and Install Dispenser Transfer Systems Performance Based Skill Assessments 2019

5.1 Design and Install Dispenser Transfer Systems Performance Based Skill Assessments 2019 Section One: Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Design Dispenser Transfer System Determine