CPTC Capability Statement_Competence Based Training in CPTC_R8_20100604

Training Services

Chemical Process Technology Centre

Singapore

Competence Based Operations & Maintenance Training & Assessment

for the Oil, Gas and Petrochemical


Operations & Maintenance

for the Oil, Gas and Petrochemical Industries


Competence Based Training & Assessment Chemical Process Technology Centre


Located in the heart of Jurong Island, Singapore, the Chemical Process

Technology Centre (CPTC) provides Competence Based Training focusing on the

skills development and assessment of operations and maintenance personnel

for the oil, gas and petrochemical industries.

CPTC provides:

• New entrants to the oil, gas and petrochemical industries with a set of

competencies by the provision of world class competence based training

and assessment, this training is open to local Singaporean and overseas

clients;

• Opportunities for working professionals in the industry to upgrade and

enhance their knowledge and skills with the latest industry technologies

developments;

• A strategic international training infrastructure aimed at developing

specialist manpower to support the growth of the global oil, gas and

petrochemical industries.

CPTC is owned by the Singapore

Economic Development Board (EDB)

and managed by Petrofac Training

Services, the training arm of the

Petrofac Group. CPTC is also a fully

accredited Continuing Education

Training (CET) Centre by the

Singapore Workforce Development

Agency (WDA).

CPTC is the first training centre in the world to contain an industry-scale

petrochemical process plant. Designed to operate as an actual production unit

in a typical commercial plant, the process unit will allow trainees to experience

real plant operations to enhance their training experience under safe and

controlled conditions.


CPTC’s Expertise

CPTC demonstrates Singapore’s and Petrofac Training Services’ commitment to

building and enhancing a world-class workforce.

CPTC’s trainers are specialists with years of industry experience in operations,

maintenance and safety; while the teaching laboratories house state-of-the-art

equipment constantly upgraded to suit requirements of the industry.

Process Technicians working in a

chemical process plant are often

required to do specialised tasks

such as climbing vertical ladders,

operating block valves and

distributed control systems. CPTC’s

trainers impart their expertise and

experience to ensure trainees are

able to perform competently as

such. One of the option companies

tapped on, is engaging our trainers’

expertise to conduct Aptitude

Screening Tests in their pre-employment screening process, to gauge the

suitability of their job applicants to work in a process plant environment.

In addition to live-plant training, CPTC also conducts specialised courses for

working professionals in the oil, gas and petrochemical industries. They

include:

• Distributed Control System

• Process Measurement and Control

• Rotating Equipment

• Critical Incident Management

• Emergency Response and Crisis Management

• Health, Safety and Environmental


CPTC worked closely in partnerships with our clients to allow customisation in

the courses so as to cater to the specific training needs of companies.

In addition to delivering top notched training courses, CPTC’s expertise had

been further tapped by governmental agencies and industry partners to lead

the quality of the workforce through the following areas:

Development of Competency Frameworks and Qualifications

Utilising its experience in developing competency frameworks for the workforce

in its global engineering projects, Petrofac Training Services partnered with the

Singapore Workforce Development Agency to develop Singapore Workforce

Skills Qualifications (WSQ) program for the chemicals industry in Singapore.

WSQ is a robust and integrated continuing education and training system in

Singapore. Designed to build industry competencies, it is founded on best

international practices and validated by industries and employers. WSQ is

designed to facilitate adult learning, make skills upgrading more accessible to

the workforce and provide career progression pathways for them. It also aims

to equip the workforce with the necessary employability, industry and

occupational skills to remain competitive and add value to the organisation.

Industry partners have further engaged this expertise through CPTC to bring

their workforce’s competency-based learning to an entirely new level.

Design and Development of Customised Dynamic Process Training Skids and

Pilot Plants

Leveraging from Petrofac’s experience in providing real life solutions to the

industry, CPTC offers expertise in engineering design of control systems with

the latest instrumentation technology.

Over the years, with this expertise, CPTC has delivered many Dynamic Process

Training Skids which resulted in realistic process models giving real-time

training modules. These training skids are

designed to the customer’s requirement,

based on the competence levels required

by the plant users. Such designs include

Liquid/Gas Separation System,

Temperature, Flow and Level Control

Systems with complex loops having multi

cascade and feed forward controls,

Custody Transfer Flow Metering Systems.


CPTC’s Facilities

CPTC is a state of the art training centre with a fully operational life size

Kerosene Distillation Unit (KDU), simulation labs, mechanical and

instrumentation labs and e-learning classrooms.

Process Plant – Kerosene Distillation Unit

CPTC has a fully operational life size Kerosene Distillation Unit (KDU) complete

with:

• Distillation Column

• Hot Oil System

• Fired Heater

• Tank Farm

• Cooling Water System

• Nitrogen System

• Air System

The KDU has a complete arrangement of exchangers, rotating equipment,

instrumentation and is monitored and controlled from a fully functional

Centralised Control Room with an advanced Distributed Control System (DCS).

The CPTC Process Plant provides a unique opportunity to deliver competence

based Operations and Maintenance training to personnel starting their career in

the oil, gas and petrochemicals industry or requiring re-skilling or skill

enhancement. Using in-house or client specific competence based training

curriculum and systems, CPTC provides the ideal environment to develop

competent Operations and Maintenance personnel.

This entire plant, in fact, functions as a giant learning area, outside of the

classroom.


Distributed Control System Laboratory

In collaboration with Honeywell, the Distributed Control Systems laboratory

houses a dynamic process simulator for oil, gas and petrochemicals industries.

The lab provides trainees the competencies in engineering programming,

configuration and implementation for DCS. Trainees will also get training in DCS

maintenance and troubleshooting in a fully equipped lab with state-of-the-art

control hardware and software with modern man-machine interface for

efficient, safe and optimal plant control.

All trainees have plenty opportunities to work on real-time, "life-like"

processes, without the accompanying dangers of a normal plant operation, in

the safety and comfort of the air-conditioned laboratory.

Instrumentation, Automation and Control Laboratory

The Instrumentation, Automation and Control Laboratory houses a full range of

instrumentation for a series of courses on process control and measurement.

These are foundation courses for those working in the process industry. The lab

consists of process plant measuring devices, control elements, process

analyzers and other measurement and control related equipment.

The laboratory provides hands-on

experience on standard Process

Instrumentation and Control Systems,

e.g. sensors, transmitters and

transducers; control of flow, level,

pressure and temperature; PID

controllers and control valves.

Trainees are exposed to control

strategies for pilot plant operations,

e.g. process dynamic studies;

feedback control; ratio control; cascade control; split range control; controller

tuning.


Rotating Equipment Laboratory

Collaborating with Flowserve, CPTC’s Rotating Equipment Laboratory offers

courses for industry participants on pumps, mechanical seals and system

reliability in a spacious training and well equipped environment.

In the static section, trainees are

expected to get fully hands-on with

the wide range of lab equipment eg.

pumps, valves and mechanical seals.

These include performing

experiments, doing measurement

checks, assembling and disassembling

equipment and performing integrity

checks. The trainees would be

equipped with competencies to cope

with on-site or off-site situations

encountered in their work. The experience of the trainees is further enhanced

with the various assortments of pumps, seals and valves models on display and

these models are exhibited in the form of cutaways, or in full or partially

assembled states.

In the power lab, arrays of six pumping systems are available for trainees to

perform different types of lab exercises. The training laboratory is designed

for hands-on training, a special

feature being the “see through”

pump design which allows

trainees to have a better

understanding of how a pump

works as well as how pump

cavitation occurs. Trainees also

learn about Net Positive Suction

Head (NPSH) principles, which

are important in oil refinery and

chemical process plant

operations. By seeing and

running an actual running pump, the trainees can truly gained knowledge in

pump hydraulics, pump performance curves, causes of mechanical seal and

rotating equipment failure.


Critical Incident Management Training Suite

As part of the expansion plans and bringing new expertise into Asia, CPTC now

houses a truly new state-of-the-art Critical Incident Management Training

Centre (CIMT). The development of both the facilities and courses had been

carefully planned and based on extensive customer research.

The CIMT has its own emergency

management training software

which can be customised for

clients’ needs. Fully equipped

with audiovisual capabilities and

key event and tally boards. The

whole environment aims to

replicate emergency situations

ranging from a simple false

alarm to full-scale facility

abandonment. Built as a third

generation concept, the CIMT is fully connected with web cams positioned at

various strategic points of observations for record and if required, the training

manager can observe their delegates’ training at any part of the world.

To guide the delegates’ training, observation rooms with its one-way mirror

ensure that the delegates’ performances are assessed and guided by our

qualified instructors and assessors.

Safety Centre

Designed to closely reflect the needs of our clients and the real life

circumstances in which they operate, CPTC Safety Centre allows our trainers to

deliver high quality safety training for the Oil, Gas and Petrochemical

Industries.

Equipped with the latest engineered training apparatus, trainees will have

hands-on experience in real life workplace scenarios balanced with classroom

teaching. Courses are accredited to meet or exceed all relevant international

standards and Code of Practice requirements. Course levels range from basic

understanding of health and safety to tailored specific company inductions such

as Safe Systems of Work, to supervisory and further to senior management level

HSE courses.


Singapore Petrochemical Industry Career Centre

As a strong partner to WDA as a Continuing Education Training Centre (CET),

CPTC provides its WSQ graduates career advisory services and placement

opportunities with partners in the chemical industries.

With a recognised WSQ qualification, CPTC added value to its WSQ graduates

through its Career Centre. The Career Centre will send the graduates’ resumes

to our participating partners and will help our shortlised graduates to prepare

for their interviews, provide career advice and further development

opportunities.

Auditorium, Function and Seminar Rooms

As value-added service especially to companies on Jurong Island, CPTC also

provides facility rental services at attractive rates. CPTC’s list of facility

resources include:

• 200-seater auditorium

• Function room for receptions or mini-exhibitions and launches

• Seminar rooms for small-group training

The auditorium, function and seminar rooms are fully-equipped with audio-

visual equipment.


© Petrofac 2010 10

Competence Based Training & Assessment

CPTC under the management of Petrofac Training Services provides an

extensive range of competence based technical training and assessment,

focusing on skills assessment and development of Operations and Maintenance

personnel for the oil, gas and petrochemical industries.

With the advantage of having a hydrocarbon process plant solely for training

purposes, CPTC conducts competence based operations and maintenance

training including shift rotation, Permit to Work with task risk assessments,

start-up and shut-down exercises, emergency response and fire drill exercises,

offering trainees a unique experience to gain hands-on training on a live plant.

The following outlines the Competence Based Training & Assessment regime

each trainee in CPTC undergoes:

Plant Pre-Operation

Each trainee starts off their training with the main objective of gaining full

competencies to eventual operation of the plant safely and successfully. In

order to achieve that, pre-operation preparation and understanding of the

plant/ system operation will be covered. The trainees will be organised into

teams where the tasks of preparation with task risk reviews will be conducted.

The aim here is to start the plant/ system from cold, in many ways similar to a

commissioning activity, the program will include:

• Understanding the purpose of the process system

• Equipment and process identification and description

• Review of process system

• Review of shut-down and permissives to start through Operating

Manual/ Cause and Effects Narratives

• Review Procedures for:

– Pre-start checks

– Process start

– Process stop

– Emergency shut-down


– Upset conditions

– Lock out/tag out

– Maintenance Isolation

• Review Plant/ System Readiness

• Availability of air and power

• Electrical motor start checks/ rotation check

• Instrument function checks

• Sign off available for start-up

Control Room Operations

The fully functional Control Room is also a fully integrated training module for

trainees offering them the unique opportunity to experience a real control

room environment complete with Operator Stations, Alarm Annunciators, Event

and Report printers, Radio Interface with Plant, Remote Shutdown, and

Operational CCTV. The integrated training in the Control Room equipped the

trainees with the following essential control room operations competencies:

• Operations and Maintenance Interface

• Permit to Work procedures

• Situation room for Tool box talks

• Plant and or system start-up

• Navigation of process graphics/ alarm summary pages/ tuning pages

• Monitoring process parameters/ alarms


© Petrofac 2010 12

• Switch controllers from manual to auto

• Switch controllers from Auto to Cascade

• Adjust set points and observe process response

• Acknowledgement of alarms and alarm/ event reporting

• Data storage and transfer

• Radio protocol from Control room to field and vice versa

• Creation of Fire/ Gas Alarms, response and muster assembly

• Plant or system shut-down

The competencies gained from this training enables the trainee to better

interface with the plant processes/ systems/ maintenance personnel and the

DCS/ information systems.

Plant Operations

Trainees with a strong foundation in place will then be equipped with the

competencies to prepare for the actual start up and operation of the process

plant. The trainee will also be tasked with “on-line” monitoring and control,

and also interface with the maintenance group just like what a process

operator will be carrying out in their role. The competencies will include:

• Plant or System Start-up

• On Line Monitoring and Control

• Field Operator: Monitoring and Logging

• Sample Collection

• Routine Checks

• Maintenance intervention: Tool Box talks, Permit to Work, Task Risk

Assessment

• “Situation” developments, process alarms, Fire/Gas alarms

• Plant Shut-down

The trainees will be grouped into shift teams to perform shift work. Night shifts

can be arranged to increase the authenticity of the training. All training will

be “Competence Mapped” against the relevant Job Profiles, using the building

block determination headings.


© Petrofac 2010 13

Petrofac Competent Workforce Scheme

To manage and implement competency based training, through the years of

close partnerships, Petrofac provides clients with a complete managed solution

in respect of competence development for Operations and Maintenance

personnel through the Petrofac Competent Workforce Scheme (PCWS).

The purpose of PCWS is the successful development of personnel by the

application of ‘blended and accelerated learning’ methodologies. It focused on

the person’s job tasks and functions on a specific asset or facility. Unlike most

other forms of training programs, it is based not on time but the person’s

ability to demonstrate competency.

This is achieved by the utilisation of a range of classroom based and CBT

training modules designed to provide the necessary underpinning knowledge for

new entrant and discipline technicians entering into the oil, gas and

petrochemical industries. The curriculum provides solid knowledge and skills

foundation in Production, Instrument, Electrical and Mechanical Operations.

This is combined with a highly structured ‘On the Job’ training program, which

ensures that the main focus of learning is both experiential and relevant to

their job requirements and provides them with ‘real’ skills and experience.

The three entry levels for the PWCS are:

• Apprenticeship entry

• Graduate/cadets entry

• Cross discipline/non-oil and gas discipline entry

PCWS has the flexibility to be aligned to a recognised industry or national

qualification or enterprise-based competencies. If the client does not require a

qualification outcome or have a structured Competency Assurance Program,

Petrofac has a ‘Competency Catalogue’, which contains competencies to suit

the oil and gas ‘up’ and ‘down’ stream facilities, petrochemical and energy

sectors, from which a ‘Competency Portfolio’ can be derived to meet the needs

of a specific job function on an asset or facility.


© Petrofac 2010 14

The scheme comprises three main elements:

• Competent Person Profile (CPP) - STRUCTURE

• Pathway to Competence (PTC) - METHODOLOGY

• Competence Management System (CMS)- RECORDING AND TRACKING

CMS

Competence Management

System

Training Scheduling/

Booking

Tracking Assessment Outcomes

Electronic Data

Base

Annual Training

Plan

Status Reports

Competency /Training

Matrix

CPP

Competent Person Profile

Personal Skills Audit

Job/ Position

Description

Competency Catalogue

Course/ Program

Catalogue

PTC

Pathway To

Competence

On-The Job

Training

Computer

Based Training ‘Face

To Face’

Assessment

Vendor/ Supplier Training

Competency

Portfolio

Competency

Profile

Methodology


© Petrofac 2010 15

Petrofac Training Courses and Programs

The following courses and programs are delivered by Petrofac Training either at

CPTC or at other Petrofac Training Competency Centres. Some course content

and duration are dependent upon client’s needs and the level of competence

required, and may be customised if necessary.

Process Plant Operations

Course Type Course Code Duration

WSQ Certificate in Process Technology (Chemical) (Full-time)

CT2101 6 weeks

WSQ Certificate in Process Technology (Chemical) (Part-time)

CT2102 10 weeks

WSQ Higher Certificate in Process Technology (Chemical) (Full-time)

CT2201 8 weeks

WSQ Higher Certificate in Process Technology (Chemical) (Part-time)

CT2202 12 weeks

WSQ Certification in Process Technology (Chemical) (Customised)

CT 2203 Customised

Chemical Process Operations Training (Industry) CT5105 6 days

Chemical Process Familiarization Course CT5107 5 days

Process Equipment And Operations Course CT5108 3 to 30 days

Chemical Process Operations Training (NITEC) CT5000 10 weeks

Chemical Process Operations Training (Diploma) CT5003 6 weeks

Aptitude Screening Test for Process Operator CT5104 1 day

Organic Chemistry for Hydrocarbon Process Industry 1 CT5108a 5 days

Organic Chemistry for Hydrocarbon Process Industry 2 CT5109 5 days

Organic Chemistry for Hydrocarbon Process Industry 3 CT5110 5 days

Basic Sciences for Chemical Process Operations CT5111 5 days

BTEC Level 1 Certificate in Process Technology CT6100 5 weeks

Distillation Principles and Equipment CT5112 3 days

Fundamentals of Fired Heaters CT5113 2 days

Heat Exchanger Operations CT5115 3 days

Heat Exchanger Principles and Equipment CT5114 2 days

Operate Compressors and Associated Equipment CT5116 3 days


© Petrofac 2010 16

Operate Distributed Control System for Control Room Operators

CT5117 5 days

Process Plant Maintenance


General Maintenance

Basics In Process Plant Maintenance Training CT5201 4 to 12 days

Perform Overhaul & Major Maintenance of Control Valves in a Process Plant

CT5202 3 days

Perform Overhaul & Major Maintenance of Rotating Equipment in a Process Plant

CT5203 3 days

Electrical

A.C. Systems and 3 Phase Systems CT5301 1 day

Fundamentals of AC Generator CT5302 1 day

Fundamentals of DC CT5303 1 day

Perform Electrical Isolation for Equipment Maintenance

CT5305 1 day

Principles of Electrical Safe Working Practices CT5306 1 day

Mechanical

Fundamentals Of Centrifugal Pumps CT1000 2 days

Improving Pump, Mechanical Seal And System Reliability

CT1001 3 days

Fundamentals Of Mechanical Seals CT1100 2 days

Operating Mechanically Sealed Equipment CT1101 1 day

Analyzing Mechanical Seal Failure CT1102 1 day

Process Control & Instrumentation

Process Measurement and Control Appreciation PMCA / CT3000

5 days

Industrial Process Measurement INPM / CT3001

4 days

Industrial Process Control INPC / CT3002

5 days


© Petrofac 2010 17

Distributed Control System


Operator

LCN/UCN/GUS for Plant Operators CT4000 5 days

Honeywell Control System Overview CT4002 2 days

Experion PKS Operator CT4050 3 days

Maintenance

UCN/HPM Maintenance CT4005 5 days

TPS System LCN Maintenance CT4006 5 days

HPM Maintenance Refresher Training CT4007 3 days

FSC Controller Maintenance CT4031 3 days

LCN/UCN/HPM(GUS) Maintenance CT4009 5 days

Implementation

TPS System (GUS) Display Builder/ Safeview Implementation

CT4008 5 days

GUS/LCN/UCN Implementation using DEB CT4003 10 days

HPM Points and CL Implementation CT4004 5 days

AM/APP/CL Implementation CT4010 5 days

Uniformance R210 PHD System Administration CT4040 5 days

Administration of Uniformance R210 PHD Background Applications

CT4041 2 days

Uniformance Desktop End User Training CT4042 3 days

FSC Controller Implementation CT4030 5 days

Experion PKS Server Engineering and Configuration CT4051 5 days

Experion PKS Control Execution Environment C300 CT4052 5 days

Experion PKS Graphic Design & Building CT4053 4 days

Refresher

GUS/LCN/UCN Implementation Refresher CT4001 5 days


© Petrofac 2010 18

Health, Safety, Security & Environmental


Oil/Petrochemical Safety Orientation Course for Workers (English)

CT0002 1 day

Oil/Petrochemical Safety Orientation Course for Workers (Mandarin)

CT0005 1 day

Hot Work Gas Tester Course CT0006 1 day

Bridging Course for Confined Space Safety Assessor CT0007 3 days

Fundamentals of Quantitative Risk Assessment CT0011 2 days

Process Plant Permit to Work Systems CT0008 3 days

Qualitative Risk Assessment CT0010 2 days

Safety Equipment in a Process Plant CT0009 3 days

NEBOSH Certificate in Health and Safety for the Oil and Gas Industry

CT0013 5 days

Behavioural Safety Programme for Control Room Operator

CT0012 2 days

Critical Incident Management Training


Major Emergency Management Training PTSAP-01-2010 / CT7000

4 days

OIM Controlling Emergencies (Coaching & Assessment) PTSAP-12-2010 / CT7001

2 to 5 days

Control Room Operators Emergency Response Training PTSAP-13-2010 / CT7002

4 days

Control Room Operators (Coaching & Assessment) PTSAP-14-2010 / CT7003

2 days

Emergency Management on Normally Unattended Installations

PTSAP-15-2010 / CT7004

3 days

Certified Track in Emergency & Crisis Management (Supervisory)

CT7005 15 days

Certified Track in Emergency & Crisis Management (Operational)

CT7110 15 days


© Petrofac 2010 19

Emergency Response & Crisis Management


Incident Management Training PTSAP-02-2010

/CT7100

2 days

Crisis Management Training PTSAP-03-2010 / CT7101

1 day

Chemical Hazard Awareness Training PTSAP-04-2010 / CT7102

1 day

Media Awareness Training PTSAP-05-2010 / CT7103

2 days

Family Response Training PTSAP-06-2010

/CT7104

1 day

Business Continuity Management PTSAP-07-2010 / CT7105

1 day

Developing Emergency Response Procedures PTSAP-08-2010

/CT7106

1 day

Design & Conduct of Emergency Response Exercises / Drills

PTSAP-09-2010 / CT7107

1 day

Introduction to Incident Command System (ICS) PTSAP-10-2010

/CT7108

1 day

Hazard Awareness for Emergency Responders PTSAP-11-2010 / CT7109

1 day

Please call and email us to get the latest copy of course directory and

quotation.


Petrofac Training Pte Ltd


81 Jurong Island Highway

Singapore 627837

Telephone: +65 6880 2000 / +65 6880 2008 / +65 6880 2057

Email: [email protected]

Website: www.cptc.edu.sg / www.petrofactraining.com

Documents

CPTC Capability Statement_Competence Based Training in CPTC_R8_20100604