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The Process Technician

The Process Technician. Introduction to Process Technology PTAC 1302 WCJC – Fall 2014. Topics. Where Do They Work? Job Outlook What They Do (Roles) Responsibilities Qualifications – knowledge and skills, interpersonal skills, education Physical Capabilities Needed

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The Process Technician

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  1. The Process Technician Introduction to Process Technology PTAC 1302 WCJC – Fall 2014

  2. Topics • Where Do They Work? • Job Outlook • What They Do (Roles) • Responsibilities • Qualifications – knowledge and skills, interpersonal skills, education • Physical Capabilities Needed • Mental Capabilities Needed • The Shiftwork Life • Workforce Organization • Future Trends

  3. Where Do They Work? Process Industry Pharmaceuticals Refining Food/Bev Pulp/Paper Chemical Energy Oilfield Pipeline Traditional Nuclear Alternative

  4. Job Outlook • Over 500,000 operators and 250,000 lab techs in U S • Although sub-sectors of the process industry can be very cyclical – meaning business can boom, then crash the forecast for jobs into the future is bright • Baby Boomers Retiring • Alternative/Green industries emerging • Careers beyond control room – research, sales, support jobs

  5. Job Oulook • Wages some of the highest – “Gold” Collar • Petrochem – finishing entry $12.00 • Petrochem – manuf entry $22.00 - $28.00 • Nuclear – entry $31.00 - $50.00 • Benefits

  6. Job Outlook • There is the threat of companies continuing to move operations and JOBS out of the U.S. due to • Rising labor costs • Oppressive federal and state regulation • Raw material needs • Transportation costs as global markets shift

  7. Job Outlook • To learn more check out web sites such as: • www.workintexas.com • www.careerbuilder.com • Or the myriad of recruiting sites like www.monster.com

  8. What they do The Process Technician starts, stops, monitors, maintains, controls, troubleshoots, problem-solves, improves, evaluates, analyzes, gas frees, air frees, communicates about, trains others on, and writes procedures………….

  9. ………….for Furnaces, turbines, pumps, compressors, exchangers, crystallizers, flakers, dryers, desalters, boilers, reactors, dehydrators, distillation columns, extruders, pelletizers, blowers, evacuators……...

  10. ……..How • Safely • Efficiently • Environmentally compliant • While working as a member of a team • With a focus on the business goals • In all types of weather………...

  11. Summary of Responsibilities • Monitor and control process (more) • Minor maintenance, troubleshoot and problem solve (more) • Administrative activities • Perform with a focus on Safety, Health, Environment and Production • Practice quality • Training/certification and continually learning

  12. Monitor and Control Process • Sample and process streams • Inspect equipment • Start, stop, and regulate equipment • Respond to changes • Respond to emergencies or abnormal operations • Document activities, issues, and changes

  13. Perform Maintenance • Change or clean filters and strainers • Prepare equipment for repair • Lubricate equipment • Monitor equipment performance • Vibration and temperature analysis

  14. Troubleshoot and Problem Solve • Apply root cause analysis • Participate in corrective action teams • Statistical Process Control (SPC)

  15. Qualifications 1. Basic Skills 2. Technical knowledge and skills 3. Interpersonal skills 4. Physical capabilities 5. Mental capabilities 6. Education

  16. Basic Skills • Reading • Writing • Listening • Interpersonal Skills & Communication • Computer Technology • Math • Science

  17. Basic Skills • Punctuality • Multitasking • Problem Solving • Safety Awareness and Action • Quality Awareneess and Action • Environmental Awareness and Action

  18. Technical Knowledge, Skills, and Abilities • Math. Science, Computers • Operation, maintenance, and troubleshooting of process equipment • Key regulatory standards and laws • Communications skills: reading and writing, industry-related materials

  19. Qualifications:Interpersonal Skills • Communicate effectively - reading, writing, listening • Positive attitude towards job, others, self • Respect for safety of self and others • Maintain composure in high stress situations • Responsible • Reliable – punctual and good attendance • Appreciation for diversity • Provide and respond to feedback positively

  20. Physical Capabilities Ability to • Work in high noise level areas [above 85 dB] • Lift, climb stand for long periods of time • Work at elevated heights • Wear personal protective equipment (PPE ] • Perform in all types of weather - heat, cold, rain • Handle demands of shift work • Perform under pressure / high stress situations • Perform physically demanding tasks

  21. Mental Capabilities • Analytical • Can process technical information correctly and quickly if needed • Critical thinking • Problem solving • Can tolerate longs hours and flexing work hours (nights)

  22. Education • Some areas – HS diploma or even GED • High school courses, college credit options • Two-year Associates Degree in Process Technology preferred - REQUIRED by MANY AREA EMPLOYERS • Math, Science, English • Computer skills: spreadsheets, word processing, database applications • Continuing Education – be a lifelong learner

  23. Work Environment • Get to work and work regardless of weather • Usually start outside • Work outside during turnarounds and upsets • Inside – control room, lab

  24. The Shiftwork Life • Not usually your “8 to 5” job • Most plants are on rotating 12 hr shifts • Even longer days during turnarounds, new unit/equipment start-ups

  25. Impact on Shift Workers • Fatigue - Biological time clock is like permanent jetlag • Reduced attention span • Reaction time slowed • Body clock and work schedule conflict • Non-traditional life outside of work

  26. Potential Impacts of Shift Work • Physical Health • Emotional Health • Family Problems

  27. Taking Care of Yourself • Establish as regular a schedule as possible • Create a day-sleeping environment • Take naps when possible • Compensate for lower awareness • Only light snacks in the 2-6 am/pm period • Avoid stimulants, alcohol, caffeine

  28. Union/Non-Union • Collective Bargaining

  29. Future Trends • Continued emphasis on preventive maintenance of equipment • Broader span of duties – example distribution functions, lab analysis • More involvement in process control and business decisions • More computerization and automation • Continuous upgrading of skills and knowledge

  30. Review Questions • Page 40 – Introduction to Process Technology (Thomas – 2010)

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