THE REPUBLIC OF LITHUANIA MINISTRY OF EDUCATION AND SCIENCE MINISTRY OF SOCIAL SECURITY AND LABOUR VOCATIONAL EDUCATION AND TRAINING STANDARD FOR AN OPERATOR OF TECHNOLOGICAL OIL - REFINING EQUIPMENT Vocational education level 3 Vilnius, 2008
EUROPOS SĄJUNGA PROFESINIO MOKYMO METODIKOS CENTRAS Europos socialinis fondas ŠVIETIMO IR MOKSLO MINISTERIJA KURKIME ATEITĮ DRAUGE! Development of the Standard was financed by European Union and by the Republic of Lithuania under the Project No BPD2004-ESF-2.4.0-01-04/0156 Development of the System of VET Standards Development of the Standard was coordinated by the Methodological Centre for Vocational Education and Training Profesinio mokymo metodikos centras, 2008
APPROVED by Order No ISAK- 1872/A1-209 of the Minister Education and Science of the Republic of Lithuania and of the Minister of Social Security and Labour of the Republic of Lithuania of 26 June, 2008 VOCATIONAL EDUCATION AND TRAINING STANDARD FOR AN OPERATOR OF TECHNOLOGICAL OIL - REFINING EQUIPMENT I. DETAILS OF THE VET STANDARD 1.Vocational Education and Training level 3 rd 2.State code S352404. 3.Qualification awarded operator of technological oil-refining. 4.Basic education secondary. II. CONTENT OF THE VET STANDARD 5. Brief description of occupational activity 5.1. The VET Standard for an Operator of technological oil - refining (hereinafter referred to as the Standard ) has been developed taking into account changes on the labour market, findings of the qualification study carried out by the Standards Development Working Group and based on the experience of other countries. The present Standard serves as a basis for the development of a training programme of vocational education level 3. 5.2. The Standard establishes minimum training requirements for an operator of technological oil - refining for working in the following main activity areas: quality management of raw materials and products; management of technological ; maintenance of technological ; management of support resources; organisation of work of the technological. 5.3. An operator of technological oil - refining manages oil refining technological, ensures proper and safe use of technological ; uses control measuring and automation; controls and manages technological process during breakdowns or accidents; prepares the technological or separate technological pieces of for maintenance; produces products in line to the norms and standards; carries out the accounting and use control of raw materials, and energy resources, manages and looks after support resources; organises safe work of the technological 5.4. Successful work of an operator of technological oil - refining requires the following personal qualities: fast orientation, thoroughness, honesty, initiative, personal responsibility, diligence. 6. The objective of an operator of technological oil - refining managing oil refining technological. 7. Operator of technological oil - refining s activity areas and competences are listed in Appendix 1 of the Standard. 8. The scope of an operator of technological oil - refining s competences, training objectives and competence assessment are provided in Appendix 2 of the Standard. 9. Successful work as a operator of technological oil - refining requires the following general capabilities: 9.1. personal responsibility; 9.2. organisation skills;
2 9.3. creative skills 9.4. independent decision making; 9.5. team work; 9.6. discretion; 9.7. tolerance; 9.8. mathematic literacy; 9.9. computer literacy. 10. Final qualification assessment: 10.1. Qualification of an operator of technological oil - refining is awarded to a student who has completed the whole training programme; acquired competences defined in the Standard and has been given a positive final qualification evaluation. 10.2. In accordance with the competence assessment criteria listed in the Standard, the following is tested and evaluated: 10.2.1. during the training process - all competences defined in the Standard; 10.2.2. 3. during the final qualification assessment - selected competences, the priority is given to the following competencies: taking samples manually and automatically; setting into operation and stopping technological ; managing accidents; looking after technological during the operation; controlling the supply of resources of technological ; managing effluents, liquid and hard waste; organising safe work in the technological. 10.3. Organisation and performance of the final qualification assessment and issuance of documents is regulated by the Ministry of Education and Science of the Republic of Lithuania.
Appendix 1 to the VET Standard for a operator of technological oil - refining AREAS OF ACTIVITY AND COMPETENCIES OF AN OPERATOR OF TECHNOLOGI- CAL OIL - REFINING EQUIPMENT 1. Quality management of raw materials and products Areas of Activity Competencies 1.1. Taking samples manually and automatically 1.2. Controlling quality indicators of raw materials and production 2. Management of technological 2.1. Setting into operation and stopping technological 2.2. Managing technological processes 2.3. Managing accidents 2.4. Using measuring and automation 3. Maintenance of technological 3.1. Looking after technological during the time of operation 3.2. Preparing technological and its separate parts for maintenance 3.3. Taking part in the technological maintenance process 4. Management of support resources 4.1. Using intra-manufacturing technological communications 4.2. Controlling the supply of resources to the technological 4.3. Controlling the waste of technological 4.4. Managing effluents, liquid and hard waste 5. Organisation of work of the technological 5.1. Assessing the manufacturing environment 5.2. Organising the work place 5.3. Organising safe work of the technological
Appendix 2 to the VET Standard for a Operator of technological oil - refining LIMITS OF OPERATOR OF TECHNOLOGICAL OIL - REFINING EQUIPMENT S COMPETENCES, TRAINING OBJECTIVES AND COMPETENCE ASSESSMENT Activity Areas 1. Quality management of raw materials and products Description of Competencies Competencies Limits of Competencies 1.1. Taking samples manually and automatically 1.2. Controlling quality indicators of raw materials and production Sample taking manually and automatically. Sample adapter, sample collectors. Safety at work requirements when taking samples. Characteristics of raw material, reagents, production and other additional materials. Oil products. Standards and specifications. Laboratory analysis methods and. Laboratory quality control of raw materials Training Objectives 1.1.1. Knowing sample definitions and managing sample taking technique 1.1.2. Working with sample taking technique 1.1.3. Handling samples 1.2.1. Knowing and controlling raw materials and product quality 1.2.2. Correcting technological regime parameters with regard to the data of laboratory analysis and flow analysers 1.2.3. Beign aware of the long-terma and short-term risks of the changes in raw materials 1.2.4. Assessing the influence of product quality changes to the Competence Assessment Explained sample definitions. Safely taken sample manually and automatically. Explained threats that may occur during sample taking. When carrying out the task correctly used sample taking. Handled sample. Explained compositions and features of oil and oil products. Analysed and compared with standard ones quality indicators of raw materials, production, reagents and additional materials. Corrected technological regime parame-
2. Management of technological 2.1. Setting into operation and stopping technological and production. Norms of technological regime and quality control of interim products. Influence of possible/ likely quality deviations of raw materials and products on the course of technological processes and the risks. Preparation of the technological for operation. Setting the technological into operation and stopping it: during the cold and hot season; manually, by remote and automatic means. Technological links between seperate production units, between technological, blocks (sections). technological and final production 2.1.1. Understanding the structure of technological complex 2.1.2. Preparing technological for operation and setting it into operation 2.1.3. Stopping technological by a regular procedure and in the case of an accident ters with regard to the quality indicators. Listed possible risks and their reasons and consequences. Carried out extended analysis of one soecific area on the basis of a risk analysis and all possible consequences assessed. Established technological relations between separate technology blocks and identified the influence of this relation on the operation of technological. Listed stages of preparing technological for operation. Listed and described stopping operations and their sequence of technological machinery by a regular method and in the case of an accident. Assessed action and safety at work procedures in the modelled situations. 2
2.2. Managing technological processes Oil refining technologies. Oil refining technological processes. Technological schemes of technological. Automatic operation principles and schemes of technological. Norms, threshold values of technological regime. Blocking and alarm systems. Efficient work organisation in the technological. Technological documentation. 2.3. Managing accidents Possible technological process interruptions and 2.2.1.Managing oil refining technologies and processes 2.2.2. Managing technological regime and safely and efficiently using technological and machinery 2.2.3. Establishing material and thermal balance of a technological 2.2.4. Reading and supplementing technological documentation 2.3.1. Analysing possible technological process interruptions and Explained set into operation/ stopping features during the cold season. Read oil refining technological schemes. Explained primary and secondary oil refining technological schemes and technological and machinery use features. Explained chemistry of thermal and catalytic processes. Recorded technological regime parameters. Established material and thermal balance of a technological. Explained operation principles of a blocking and alarm system. Explained automatic regulation principle of a process. Coordinated modelled technological regime. Listed consequence elimination procedures 3
2.4. Using measuring and automation the ways to eliminate it. Possible accident situations and personal actions during them. Acceptance or derivation procedure of illconditioned products. Decontamination methods of hazardous materials during accidents. Consequence elimination plans in accident situations. Usage of accident prevention tools. Principles of operation of control and measurement, inspections. Automation management tools and schemes of technological processes. Regulation valves. Flow quality analysers. Management of technological process using managing the methods of their elimination. 2.3.2. Forecasting accident situations and stopping production object in the case of an accident 2.3.3. Knowing consequence elimination plan in the case of an accident 2.3.4. Accept or derive illconditioned products 2.3.5. Using accident prevention tools 2.4.1. Knowing purpose, operation principles of the main control and measurement tools and inspection frequency 2.4.2. Using control measurement and automation 2.4.3. Using flow quality analyser results 2.4.4. Understanding operation principles of modern automation technologies in the case of an accident. Listed product, material decontamination methods in the case of an accident. Eliminated possible modelled technological interruptions. Accepted or derived ill-conditioned product. Explained role of blocking, alarm systems, warning and managing situations. Explained use of accident prevention tools during accidents. Explained objectives of training on how to work with the. Explained measurement and automation everyday maintenance and repair principles. Corrected technological regime parameters under the modelled situation. Explained measurement and 4
3. Maintenance of technological 3.1. Looking after technological during the time of operation 3.2. Preparing technological and its separate parts for maintenance computer software. 2.4.5. Managing software applied in the management of the technological process Constructions, principles of operation, characteristics of technological machinery and. Technical maintenance organisation principles. Maintenance plan (frequency of inspections, scope, methods) of technological machinery and and maintenance procedures. Equipment technical documentation. 3.1.1. Knowing technological and machinery constructions and operation principles 3.1.2. Observing technological and machinery conditions during the operation 3.1.3. Maintaining technological and machinery 3.1.4. Knowing the principles of maintenance of potentially hazardous 3.1.5. Taking part in the tightness and strength tests of pressure (tanks, pipelines, steam boilers) Preparing technological for repair. Procedures of preparation typical for repair. Written documentation of repair works. Possible problems and 3.2.1. Preparing the territory of the technological for repair 3.2.2. Preparing specific of technological machinery (reactors, regenerators, vacuum columns, machinery, etc) for repair 3.2.3. Knowing the technology of loading and unloading of a catalyser automation operation principles. Managed modelled situations applying software for managing technological. Listed maintenance procedures, their frequency, scope and methods of technological and machinery. Listed maintenance features of technological and machinery. Described technical maintenance organisation principles. Explained procedure of organisation pressure tools tightness and strength tests and handling for use. Indicated territory preparation works of the technological for repair. Indicated preparation for repair operations, their sequence. 5
3.3. Taking part in the technological maintenance process threats during the preparation for repair stage. Materials used in the construction, of technological machinery, their features. Corosion, erosion and other processes reducing resistance. Methods of assessing construction quality. Metal works. Reading technical drawings. Procedures of assembly and dismantling of technological machinery and. (regenerated, non-regenerated) 3.2.4. Managing preparation for repair procedures of general technological parts and separate parts 3.2.5. Understanding written repair work documentation 3.3.1. Knowing used materials and their properties used in technological constructions and in their 3.3.2. Carrying out metal works, using measurement tools and being aware of fits and limits 3.3.3. Reading technical drawings 3.3.4. Knowing the procedures of repair of technological and machinery and knowing the duties of technological staff during the repair Listed safety measures when preparing technological for repair. Listed typical mistakes of preparation for repair. Explained technologies of discharge (or charging) of a regenerated or non-generated catalyser. Indicated role and content of written repair documentation. Described properties odf the used construction materials, explained limitations of their use. Measured detail parameters, applying rellevant measurement tools. Carried out metal works. Drawn and read sketches, technical drawings, and uncomplicated design and assembly drawings. Explained assembly and dismantling proce- 6
4. Management of support resources 4.1. Using intramanufacturing technological communications 4.2. Controlling the supply of resources to the technological Inter-manufacturing technology communication schemes and their usage. Technological schemes of intermediate product reservoir parks. Reservoir construction and technological. Raw material supply/ production derivation schemes. Product warehousing, loading. Interrelation with other technological and support objects. Supply of necessary resources for a techno- 4.1.1. Using inter-manufacturing technological and support pipelines 4.1.2. Using intermediary product reservoir parks 4.1.3. Knowing reservoir constructions 4.1.4. Managing raw material supply scheme 4.1.5. Managing production derivation schemes 4.2.1. Knowing and using technological electricity and other energy supply sources 4.2.2. Managing energy and other support resource supply schemes dure of technological and machinery. Explained duties of technological staff during repair. Explained intermanufacturing pipeline schemes. Managed modelled inter-manufacturing technologies pipeline switching schemes. Explained reservoir park technological scheme. Explained construction of reservoir and its. Calculated oil product mass in the reservoir. Managed modelled raw material supply scheme. Managed modelled production derivation schemes. Indicated interrelation with other technological and support objects. Explained schemes 7
4.3. Controlling the waste of technological 4.4. Managing effluents, liquid and hard waste logical (raw material, electricity, fuel, water steam, water, air, inert gas, reagents, additives) schemes. Accounting of resources ensuring operation. Environmental protection requirements. Data on the waste water that goes in the sewage. Sewage schemes. Waste water treatment methods. Waste water treatment facilities. Environmental management systems. Data on the technological effluent into the atmosphere and emission 4.2.3. Knowing the norms of recourses ensuring operation and using them efficiently 4.2.4. Carrying out resource usage accounting 4.3.1. Working under the requirements of environmental management system 4.3.2. Knowing company sewage systems and using them for the waste 4.3.3. Knowing company waste water treatment facility structure 4.3.4. Knowing waste water treatment methods 4.4.1. Controlling and recording the data of technological effluents into the atmosphere and emission from of supply of technological with energy resources, water, air and other materials. Explained main parameters of the supplied materials. Carried out consumption accounting of the raw material, support materials and energy and technical documentation handled. Explained environmental requirements. Explained environmental management role. Indicated company sewage systems and their role. Explained sewage system structure. Indicated data on the waste water that goes in the sewage system. Explained waste water treatment methods. Indicated data on the technological effluents into the atmosphere and 8
5. Organisation of work of the technological 5.1. Assessing the manufacturing environment from the ventilation systems. Industrial waste, effluents, their recycling and utilisation methods. Torch pipeline scheme. Smoke heat utilisation the ventilation systems 4.4.2. Managing torch pipeline scheme 4.4.3. Utilizing smoke heat 4.4.4. Using oil product loss reduction methods (steam collection and evening schemes, closed systems, etc). in the boiler-utiliser. 4.4.5. Handling liquid and hard waste Role of the oil refinery, work principles and the main functions. Company production organisation scheme. Service providing agencies. Industrial ownership objects (inventions, trademark, brandname, industrial design sample, industrial model, etc), and their protection. Basics in economics. Technical terms and definitions. 5.1.1. Knowing and understanding oil refining company profile, structure and the purpose of its separate units and development prospects 5.1.2. Realising technological operator functions, prospects at the oil refining company 5.1.3. Knowing economic definitions, principles and applying them 5.1.4. Using professional language terms and understanding them in a foreign language emission from the ventilation systems. Explained torch pipeline system. Explained how smoke heat could be utilised. Listed the loss reduction methods of oil products and explained their functions. Explained how liquid and hard waste is treated. Described oil refining company, its profile, structure, indicated purpose and development prospects. Explained company production organisation structure. Listed and described industrial ownership objects (inventions, trademark, brandname, industrial design sample, industrial model, etc), and the methods of their protection. Explained economic terms, principles of economics and their 9
5.2. Organising the work place 5.3. Organising safe work of the technological 10 Labour and collective agreements. Fundamentals in ergonomics. Job function of an operator of technological oil - refining oil. Production and workplace organisation principles. Written documentation meant for organising the work. 5.2.1. Knowing labour law and labour contract drafting requirements 5.2.2. Understanding production and workplace organisation principles 5.2.3. Knowing and exercising an operator of technological oil - refining duties and rights 5.2.4. Applying principles of ergonomics at the workplace Safety at work regulating documents and heath requirements. Local company documents (safety instructions). Collective and personal protection tools from the impact of hazardous factors. Specific safety tools of the technological process. 5.3.1. Knowing legal acts regulating safety at work and health requirements of the staff 5.3.2. Knowing professional risk factors at the workplace, classifying the objects with regard to the nature of risk for explosion and fire 5.3.3. Managing safety at work, fire precaution, civil safety, electric safety, gas safety tools 5.3.4.Using personal safety, working under the requirements of safety instructions application. Acquired professional language skills. Explained separate collective agreement paragraphs. Described ergonomic tools applied at the operator s workplace. Explained features of shift work, duties and rights of an operator of technological oil - refining. Explained production ands work organisation principles. Listed shift hand over procedures. Listed safety at work of the members of staff and health requirements regulating legal acts. Explained professional risk factors at technological. Described collective and personal safety measures. Listed safety at work requirements for
11 Risk classes of industrial objects,, facilities and technological process. First aid for the victims. Medical inspections and training. 5.3.5. Providing first aid to the victims seperate tasks. Described technological process, production facilities, external with regard to professional risk. Described raw materials, properties of the final production, materials and industrial watse toxicity features and risk levels. First aid provided to the victims.