TRAC Facilitator's Guide

Facilitator’s Guide

Plant Process Operator Training

Table of Contents Introduction for Facilitator ............................................................................................................................ 3 Welcome, Introductions & Icebreaker .......................................................................................................... 4 Session 1: Basic Oil Refining........................................................................................................................ 5 Session 2: Introduction to Workplace Safety ................................................................................................ 8 Session 3: Personal Protective Equipment (PPE) ....................................................................................... 10 Session 4: Fall Protection & Working from Heights .................................................................................. 13 Session 5: Hazard Recognition ................................................................................................................... 17 Session 6: Proper Use of Hand Tools.......................................................................................................... 19 Session 7: Training Conclusion................................................................................................................... 21 Appendix A ................................................................................................................................................. 22

Objectives – Plant Process Operator Training ........................................................................................ 22

APPENDIX B ............................................................................................................................................. 24 Initial E-Mail to Participants ................................................................................................................... 24

Appendix C ................................................................................................................................................. 25 Answer Keys to Knowledge tests............................................................................................................ 25

APPENDIX D ............................................................................................................................................. 27 Follow Up Evaluation E-Mail to Participants & Supervisors ................................................................. 27

Follow Up Evaluation E-Mail to Participants & Supervisors ................................................................. 28

3 - Facilitator Guide – Process Operator Training

Introduction for Facilitator The Plant Process Operator training incorporates PowerPoint presentation, interactive activities, educational videos, knowledge tests, reaction surveys, and more to be a comprehensive introduction to working at TRAC Oil Refinery. Review the overall and module-specific course objectives in Appendix A. The facilitator should keep in mind the following points:

• Plant process operators average an educational background of high school completion. All verbiage should be on a ninth grade reading level, and comprehension should be checked throughout the session.

• Each slide within the PowerPoint presentations contains a script for the instructor to use as a guide. Follow the script when presenting. (The script covers introductions to the lesson, lesson objectives, lesson summaries, slide content, etc.)

• The instructor must preview the information to become familiar with the material. • Answer student questions as they arise. (Adobe Connect allows students to “raise” their hands,

which will notify you of potential questions.) • Any knowledge assessments delivered utilizing the Poll feature in Adobe Connect should be pre-

loaded before the session begins. • Wait for all students to respond to the questions before revealing the answer. • Once the correct answer for each question has been revealed, allow discussion or questions to

occur. • When using web links, make a conscious choice to wither open a new window where the

participants can navigate the website or open the new web browser on your computer and ‘share your screen’ so the participants cannot access the Internet via the new window.

Upon confirmation of training scheduling, send e-mail in APPENDIX B to participants. This e-mail will include a link to the training site hosted in Adobe Connect. Update the participants’ names and training specifics in the e-mail prior to sending. The facilitator should have an expert grasp on Adobe Connect prior to launching the training. The facilitator must be mindful to interact with the participants the entire session, build time for the participants to interact with one another, as well as time to digest the content. Areas italicized and in blue ink in this guide are scripts for the facilitator. Adobe Connect Meeting link: http://connect.lsu.edu/tractraining/ Follow-up evaluations are located in Appendix D.


Welcome, Introductions & Icebreaker Welcome – Facilitator should be on-screen Welcome the participants to training. Put them at ease by saying this experience of using Adobe Connect may be new, but you’ll help them adjust to it in no time. Introduce Yourself Introduce yourself with your qualifications, history with TRAC, and a reason why you’re excited to be with them for these two days. Overview of Adobe Connect Tell the participants that before we start introducing each other, you’d like to do a brief overview of the program, since many people have not used the program before. Use the “Share My Screen” function so the participants can follow your mouse on screen as you highlight the different areas: The various pods: video, links, chat, share area, files, attendees, notes Top menu bar: audio, speaker, webcam, status Use this time (introductions and icebreaker) to help the participants get more comfortable with Adobe Connect. Participant Introductions Instruct the participants on how to turn on their web cam and microphone and introduce themselves to the group with their name, history with TRAC, and location of their home plant. Help them turn off their microphones after they introduce themselves. Icebreaker: What is your superhero personality? Now that everyone’s introduced himself or herself, let’s get to know one another better. Instructor should copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen. Once the quiz is complete, instruct trainees to close the browser window and return to the Adobe Connect session. Icebreaker Quiz Link: http://www.matthewbarr.co.uk/superhero/ Encourage conversation via webcam and the chat box about their superhero personalities. Transition into Training Wrap up the discussion about superheroes and transition in to the first training module. “Well we are all superheroes at TRAC because the decisions we make day in and day out save lives. Heroes don’t always wear capes, as you’ll learn in the next training sessions. Most often, our best hero is the person next to us that reminded us to put on safety glasses or noticed a fall hazard before we get to it. Let’s start with helping you gain a basic understanding of the oil refining process first. How’s that sound? Great, let’s get started.”


Session 1: Basic Oil Refining

Overview: This lesson introduces new process operators to the basic oil refining process. The overview will educate operators on the overall process at an appropriate skill level, including distillation process and manipulation of hydrocarbon molecules. Learning Objective: Employees will score an 85% or higher on the crude oil refining basics knowledge test which includes the distillation process and molecular manipulation Evaluation Method: Knowledge test consisting of twenty (20) multiple-choice questions and five (5) best answer choices Estimated Training Time: 2 hours Job Aids, Learning Aids, or References: Computer with Internet connection, Quick Time player, Microsoft Office suite installed on it Webcam Microphone Speakers Instructional Delivery: The facilitator will conduct the following six steps throughout the Lesson Plan for delivery of knowledge-based training. Notes for the facilitator are included in the PowerPoint slides’ “notes” section. Step 1: Lesson Title Talk about the purpose and importance of Basic Refining Overview. Step 2: State the lesson objectives Tell the learners what will be accomplished to complete the lesson. The objectives are: Process Operators will be able to describe the process flow of a simple oil refinery. Process Operators will be able to identify how crude oil is converted into gasoline. Process Operators will be able to identify in how a distillation column separates hydrocarbons. Step 3: Introduce the lesson Stimulate learner motivation by mentioning that in order to be an effective Process Operator, new employees must be learn how crude oil is refined. Preview the information to be presented. Step 4: Present the lesson (4A) Show the Crude Oil to Gasoline Video. • Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to

click on the link appearing in the “Links” pod on the right-hand side of their screen. Once the video is complete, instruct trainees to close the browser window and return to the Adobe Connect session.

• Link: http://www.youtube.com/watch?v=9Py8-Xy9MKo&feature=related • After the video is over, probe for discussion questions. Encourage trainees to ask questions by

clicking the “Raise My Hand” button on the top of their screen. They can also type a question in to the chat box pod along the bottom portion of their screen.


(4B) Show the narrated PowerPoint “Refinery Overview PowerPoint”

• Note: The narrated file is a video format, named “Refinery Overview.” The original PowerPoint file with notes in the “notes” section is also included in Instructor files.

• A helpful handout including larger images of some of the images included in the narrated PowerPoint are included in the “Refinery Overview Graphics” PDF. Instruct the participants to download and have available for reference, on screen or in print, if needed.

• Introduce the next section, a narrated PowerPoint presentation reviewing basic distillation processes. Remind the employees they can ask a question during the presentation by typing in the “Chat” pod.

• This video file should be run from the host’s computer suing the “Share my Screen” function. QuickTime Player is required to view the video. Prior to the sessions beginning, click the link below, download the file, and have it open and ready to play during the session. Once the presentation is complete, instruct trainees to close the browser window and return to the Adobe Connect session.

• Link:https://filestogeaux.lsu.edu/public/download.php?FILE=catherine/9179wm4aMz • After the presentation is over, probe for discussion questions. Encourage trainees to ask questions

by clicking the “Raise My Hand” button on the top of their screen. They can also type a question in to the chat box pod along the bottom portion of their screen.

(4C) Show the Petroleum Refining Basics Video • Introduce the next session after discussion from PowerPoint wraps up. • Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators

to click on the link appearing in the “Links” pod on the right-hand side of their screen. Once the video is complete, instruct trainees to close the browser window and return to the Adobe Connect session.

• Link: http://www.youtube.com/watch?v=jk0WrtA8_T8&feature=related • After the video is over, probe for discussion questions. Encourage trainees to ask questions by


(4D) Show the Distillation Tower Video – Part 1

• Introduce the next session after discussion from previous video wraps up. • Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators


• Link: http://www.youtube.com/watch?v=vscX_zawdQw&feature=related • After the video is over, probe for discussion questions. Encourage trainees to ask questions by


(4E) Show the Distillation Tower Video – Part 2

• Introduce the next session after discussion from previous video wraps up. • Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators


• Link: http://www.youtube.com/watch?v=Nd_pybvuIgc&feature=relmfu


• After the video is over, probe for discussion questions. Encourage trainees to ask questions by clicking the “Raise My Hand” button on the top of their screen. They can also type a question in to the chat box pod along the bottom portion of their screen.

Step 5: Complete the knowledge assessment Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link 1: http://www.surveymonkey.com/s/R57ZPZL • Link 2: http://www.surveymonkey.com/s/ZDNRDRY

Step 6: Level 1 Reaction Survey Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link: http://www.surveymonkey.com/s/SH6X6G9 Step 7: Summarize the lesson Once all the reaction sheets are complete, review and reinforce the key points below. After summarizing the key points, draw the lesson to a close and preview the next lesson. Key Points to Review:

• Crude oil is refined by being heated by a large furnace and sent to a distillation column • The hydrocarbons are separated by boiling points and trays located in the distillation column • Once hydrocarbons are run through a distillation column, products such as: Gasoline, diesel,

kerosene, asphalt, bunker fuel, ethylene, propylene, propane, butanes, sulfur and coke are produced.

• Crude oil is classified by density and sulfur content • Crude oil is further refined by removing impurities such as sulfur, nitrogen and metals. This

process is called hydrotreating or desulfurization. Hydrotreating uses stationary beds of catalyst to remove sulfur.

• Hydrocarbons are also chemically altered to through processes called reforming and isomerization to produce petroleum products.

• Large hydrocarbon molecules are broken down into smaller molecules by processes called Fuild Catalytic Cracking (FCCU), Hydrocracking , Delayed Coking. The FCCU uses a liquid catalyst to crack molecules. Hydrocracking uses a stationary catalyst and high pressure. Both use high temperatures

• Smaller hydrocarbon molecules are combined into larger ones by a process called Alkylation. • Alkylation is a liquid catalyst used to link smaller molecules together to form larger molecules. • Blending is necessary comply with octane specifications in different regions throughout the U.S. • No two (2) oil refineries are alike.


Session 2: Introduction to Workplace Safety

Overview: Employees are introduced to the issue of workplace safety and the Occupational Safety & Health Administration (OSHA) through discussions and exercises about workplace injuries and hazards. Learning Objectives: Define workplace safety Employees define their role in workplace safety Define why safety is important Define OSHA’s role in workplace safety Evaluation Method: Knowledge test consisting of five (5) multiple choice and true/false questions Estimated Training Time: 30 minutes Job Aids, Learning Aids, or References: Computer with Internet connection and Microsoft Office suite installed on it Adobe Connect meeting with files uploaded to meeting Poll questions pre-loaded in to Adobe Connect Instructor files for supplemental documents to share with group Webcam Microphone Speakers Instructional Delivery: The Trainer will conduct the following steps throughout the Lesson Plan for delivery of knowledge-based training. See “notes” section of PowerPoint files for detailed verbiage for each step. Step 1: Course Introduction - Instructor on screen speaking with slides also on screen Introduce safety and its importance in the workplace Step 2: State the lesson objectives. After this introduction to workplace safety, you will be able to:

1. Define workplace safety 2. Employees define their role in workplace safety 3. Define why safety is important 4. Define OSHA’s role in workplace safety

Step 3: Open Discussion about workplace safety What does workplace safety mean to you? -Open discussion via web cam or chat boxes -Only click once for slide to change; the answers will appear on next three clicks. After discussion, instructor will wrap up conversation with defining safety.


Step 4: Video at http://vimeo.com/17168514 Copy the video link to the “Web Links” Pods in Adobe Connect. Instruct participants to click video to watch it and close that browser once it’s finished. Watch video, and after video concludes, close Internet browser and return to Adobe connect. Wrap up discussion with notes on slide four. Step 5: Introduce Occupational Safety & Health Administration (OSHA) Follow information on slide notes, including previewing brochure on OSHA safety. Add www.OSHA.gov link to chat box for participants to access and browse materials, or pull up the link on facilitator’s screen and use Adobe Connect “Share my Screen” function. Step 6: Define worker’s role in workplace safety and TRAC’s culture of safety - Using best judgment for needing to check for comprehension through the lesson, incorporate pre-loaded poll questions in to lesson. For example, “Workplace Safety #1” is: Q: Examples of unsafe acts include: a. Making quick decisions b. Taking shortcuts c. Rough housing or horseplay d. All of the above (Correct answer) Use this to ask for example of these actions to check for comprehension. Step 7: Briefly summarize the lesson and introduce evaluation Step 8: Complete the knowledge assessment and reaction survey. (8A) Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the evaluation. After they complete the survey, remind the trainees to close the browser and return to the Adobe Connect session. Link: http://www.surveymonkey.com/s/8TMKRVN

(8B) Level 1 Reaction Survey: Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link: http://www.surveymonkey.com/s/8TCZTWN Step 9: Summarize the lesson; reinforce key points, and preview next module. Draw the lesson to a close: “Great job, everyone. Let’s stand up and stretch and then move right in to our next segment on personal protective equipment, a key element to safety in the workplace.”


Session 3: Personal Protective Equipment (PPE)

Overview: This module will show process operators what personal protection equipment (PPE) is required in the plant under particular condition and the reasons for PPE. Operators will distinguish between the various pieces of equipment and their appropriate uses. Learning Objectives: Identify personal protection items and their appropriate functions and applications while working in an oil refinery Demonstrate the proper way to put on, take off, adjust and wear personal protective equipment while working in an oil refinery Recall that PPE is the last line of defense against hazards Demonstrate the proper way to inspect PPE prior to use

Evaluation Method: Knowledge test consisting of true/false and multiple-choice questions as well as photo identification of PPE. Facilitator will also observe participants during activities throughout lesson for comprehension and ability to inspect, put together, and wear PPE. Estimated Training Time: 1.5 hours Job Aids, Learning Aids, or References: Computer with Internet connection and Microsoft Office suite installed on it Adobe Connect meeting with files uploaded to meeting and poll questions preloaded Props ready for demonstration in both trainee and facilitator rooms: hard had, safety goggles, safety glasses, earplugs, hard had suspension Webcam Microphone Speakers Instructional Delivery: The Trainer will conduct the following steps throughout the Lesson Plan for delivery of knowledge-based training. See “notes” section of PowerPoint files for detailed verbiage for each step. Step 1: Course Introduction - Instructor on screen speaking with slides also on screen of file named “PPE PowerPoint.” Introduce safety and its importance in the workplace. Open discussion question in “notes” section of PowerPoint. Step 2: State the lesson objectives. - Identify personal protection items and their appropriate functions and applications while working in an oil refinery - Demonstrate the proper way to put on, take off, adjust and wear personal protective equipment while working in an oil refinery - Recall that PPE is the last line of defense against hazards - Demonstrate the proper way to inspect PPE prior to use


Step 3: Video at http://www.youtube.com/watch?v=1-GEltJlgXw Copy the video link to the “Web Links” Pods in Adobe Connect. Instruct participants to click video to watch it and close that browser once it’s finished. Watch video, and after video concludes, close Internet browser and return to Adobe connect. Wrap up discussion with notes on slide four. Step 4: Continue through reminder of presentation, using the “notes” section for directions. Links needed are below. Unless otherwise noted, follow the same instruction on Step 3 for link distribution to trainees.

• Slide six video: http://www.youtube.com/watch?v=-hSv8knlBx0&feature=related • Slide nine document: http://www.grainger.com/Grainger/static/hard-hat-requirements-241.html • Slide ten video: http://www.youtube.com/watch?v=HI6kZVQRuUw • Slide 12 video:

http://www.youtube.com/watch?v=6b4KGICLTEs&list=PLB8563799F13E36BB&index=6&feature=plpp_video

• Slide 21 video: http://www.youtube.com/watch?v=ASv9sbphgSQ&feature=relmfu • Slide 22 video: http://www.youtube.com/watch?v=kuGjv8ZAfv4 • Slide 29 document: http://www.gemplers.com/docs/RespiratorDonningColor.pdf • Slide 34 document: Open PDF in trainer files named “Chemical Protectant Clothing Handout”

and use the Adobe Connect “Share my Screen” to share with trainees.

Step 5: Briefly summarize the lesson by reviewing objectives and introduce knowledge assessment and reaction survey. (5A) Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the evaluation. After they complete the survey, remind the trainees to close the browser and return to the Adobe Connect session. Link:

1. Some work areas require personal protective equipment just by entering the space. a. True b. False

2. What three items must be in your possession at all times?

a. Answer via chat or microphone: Hard hat, goggles, gloves

3. Let’s inspect our hard hat. How do we do that? (Actually do it) a. Visual Check b. Squeeze Test

4. Take a look at this coworker. What would you tell him about his PPE?

a. Pull up photograph EVAL1 PHOTO. b. Nothing should be between the hard hat and the person’s head.

(5B) From the activities in the lesson, review any areas that the facilitator found needed more time. This is up to the facilitator’s discretion. If all participants successfully completed all activities up to facilitator’s standards, no review is necessary. This is also part of the evaluation. Instructor should note if participants can appropriately identify PPE, inspect PPE, and put on PPE.


(5C) Level 1 Reaction Survey: Copy and paste the link below into the “Links pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session. Link: http://www.surveymonkey.com/s/8G8N5GR Step 7: Close lesson and preview next module. Great job, everyone! Let’s take a 15-minute break and return for the final session of the day about fall protection and working from heights.


Session 4: Fall Protection & Working from Heights

Overview: This lesson will stress the importance of safety while working from heights as well as fall protections. This module is broken down into three smaller sections with individual objectives to make it easier for the adult learners to process the information. Learning Objectives: Overall: Identify installation, testing, and inspection requirements of safety nets Identify installation, testing, strength, and storage requirements for personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness Recognize safety requirements when working from heights in specific relation to scaffolds, hole covers, fixed ladders, and aerial lifts Lesson 1: Safety Nets Identify accurate frequency in which safety nets must be inspected (in regards to wear, damage, or deterioration) Specify when safety nets are recommended as a fall protection option in terms of work surfaces’ height Define installation and testing conditions for safety nets Lesson 2: Personal Fall Arrest System Define minimal height requirements, inspection requirements, and maximum deceleration rates in which personal safety harnesses can be utilized in regards to fall protection Identify strength requirements for anchor points List four factors that must be considered for storage purposes of personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness Lesson 3: Working from Heights Objectives Recognize safety requirements when working from heights in the following areas: Scaffolds Hole Covers Fixed Ladders Aerial Lifts Evaluation Method: Knowledge test of multiple-choice questions Estimated Training Time: 1 hour 15 minutes Job Aids, Learning Aids, or References: Computer with Internet connection and Microsoft Office suite installed on it Adobe Connect meeting with files uploaded to meeting Preloaded knowledge test questions in Adobe Connect Safety harness Webcam Microphone Speakers


Instructional Delivery: The Trainer will conduct the following steps throughout the Lesson Plan for delivery of knowledge-based training. See “notes” section of PowerPoint files for detailed verbiage for each step. Step 1: Course Introduction - Instructor on screen speaking with slides also on screen Introduce fall protection and working from heights requirements and why they are important in the workplace. Step 2: State the Fall Protection lesson objectives. (Slide 3) Identify installation, testing, and inspection requirements of safety nets Identify installation, testing, strength, and storage requirements for personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness Step 3: Continue through reminder of presentation, using the “notes” section for directions. Links needed are below. Unless otherwise noted, follow the same instruction in previous lessons for link distribution to trainees.

– Slide 6 link: http://www.youtube.com/watch?v=C3FvpjC7C6k&feature=youtu.be Step 4: Introduce objectives for safety net portion of the lesson (Slide 8) and continue through the lesson. Identify accurate frequency in which safety nets must be inspected (in regards to wear, damage, or deterioration) Specify when safety nets are recommended as a fall protection option in terms of work surfaces’ height Define installation and testing conditions for safety nets Step 5: Conduct Knowledge Assessment (Slide 12) Use Adobe Connect Poll pod to complete knowledge assessment. Questions are below. Encourage discussion, via chat or microphone) with each question. Poll questions should be pre-loaded into Adobe Connect. Answers bolded below.

1. How often must safety nets be inspected for wear, damage, or other deterioration? a. Daily b. Weekly* c. Monthly

2. How far out from the working surface must a safety net be installed if the height of the working surface is 8 feet?

a. Up to 5 feet* b. 5-10 feet c. 10 or more feet

3. How often must safety nets be tested if left in one place? a. 1 month intervals b. 6 month intervals* c. Annual intervals

4. At what height is a safety net recommended for fall protection purposes? a. 2 feet b. 4 feet c. 6 feet*

5. The drop test consists of a 200lb bag of sand that is 28-32 inches in diameter. a. True b. False* (400lb bag of sand)


Step 6: Introduce objectives for personal fall arrest system lesson (Slide 13) and continue through the lesson. Define minimal height requirements, inspection requirements, and maximum deceleration rates in which personal safety harnesses can be utilized in regards to fall protection Identify strength requirements for anchor points List four factors that must be considered for storage purposes of personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness

• Slide 27 Link: http://www.youtube.com/watch?v=wQUdqE6GLEk&feature=youtu.be • Slide 36: Activity

o Facilitator should observe participants’ ability to properly inspect and wear a safety harness. This visual inspection should meet the facilitator’s standards to move on in the lesson.

Step 7: Conduct Knowledge Assessment (Slide 37) Use Adobe Connect Poll pod to complete knowledge assessment. Questions are below. Encourage discussion, via chat or microphone) with each question. Poll questions should be pre-loaded into Adobe Connect. Answers bolded below.

1. At what minimal height can personal safety harnesses be used for fall protection? a. 6 feet* b. 10 feet c. 12 feet

2. What is the required strength of anchor points? a. 1,000 lbs capacity b. 5,000 lbs capacity* c. 7,500 lbs capacity

3. Select the four factors that should be considered when storing a personal safety harness. a. Heat, chemical, ultraviolet rays, molten metal/flame* b. Ice, chemical, ultraviolet rays, molten metal/flame c. Heat, ice, chemical, molten metal/flame

4. What is the maximum deceleration distance for a personal fall protection device? a. 1.75 feet b. 2.50 feet c. 3.50 feet*

5. How often must personal safety harnesses be inspected? a. Weekly visual inspection b. Visual inspection before each use AND an annual routine inspection* c. Bi-annual visual and routine inspection

Step 8: Introduce objectives for working from heights lesson (Slide 38) and continue through the lesson. Recognize safety requirements when working from heights in the following areas: Scaffolds Hole Covers Fixed Ladders Aerial Lifts Step 9: Conduct Knowledge Assessment (Slide 45) Use Adobe Connect Poll pod to complete knowledge assessment. Questions are below. Encourage discussion, via chat or microphone) with each question. Poll questions should be pre-loaded into Adobe Connect. Answers bolded below.


1. Identify how additional fall protection requirements are communicated on scaffolds. a. Yellow tag indicating additional hazards* b. Assume that the potential necessities are in place c. Orange sticker indication additional hazards

2. What is the height requirement for personal fall protection when working over dangerous equipment that does not have equipment guards in place?

a. Required at 6 feet b. Required at 15 feet c. Required at all times*

3. Hole covers in roadways should be able to support ___ the maximum axle load of the largest vehicle expected to cross the load.

a. Same b. Twice* c. Quadruple

4. At what minimum height is a ladder safety device required? a. 12 feet b. 24 feet* c. 36 feet

5. Safety harnesses must be worn at all time when working from a manlift or scissor lift, regardless of height.

a. True* b. False

Step 10: Level 1 Reaction Survey Copy and paste the link below into the “Links pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session. Link: http://www.surveymonkey.com/s/SD2F57H Step 7: Close lesson and wrap up for the day.


Session 5: Hazard Recognition

Overview: This lesson plan is to outline hazard recognition in the workplace and present techniques to address and avoid those hazards. Learning Objectives: Identify work place hazards Define causes of work place hazards Identify unsafe actions that cause work place hazards Identify unsafe conditions that cause work place hazards Utilize five practical methods to identify, prevent and eliminate work place hazards Evaluation Method: A knowledge test will be given at the end of the lesson consisting of eight fill in the blank and one case study scenario. Estimated Training Time: 3 hours 25 minutes Job Aids, Learning Aids, or References: Computer with Internet connection and Microsoft Office suite installed on it Webcam Microphone Speakers Instructional Delivery: Hazard Recognition Techniques PowerPoint presentation incorporates PowerPoint slides with information to train employees on identifying hazards in the work place, causes, actions and conditions that contribute to hazards in the work place and techniques to identify, prevent and eliminate work place hazards. Notes for the facilitator are included in the PowerPoint slides’ “notes” section. Instructor can also use the “Draw” function within Adobe Connect to highlight the hazards in photographs. Step 1: Introduce the lesson and lesson objectives Recognize work place hazards Define Causes of work place hazards Identify unsafe actions that lead to work place hazards Identify unsafe conditions that lead to work place hazards Define five practical methods to identify, prevent and eliminate work place hazards Step 2: Present the lesson, using the “notes” section for directions. Links needed are below. Unless otherwise noted, follow the same instruction in previous lessons for link distribution to trainees.

• Slide 18 Video Link: http://www.youtube.com/watch?v=OqGAqwwjY7o&feature=youtu.be • Slide 53 Video Link: http://www.youtube.com/watch?v=3QKpVnTqngc&feature=email

Step 3: Briefly summarize the lesson by reviewing objectives and introduce knowledge assessment and reaction survey.


(3A): Knowledge Test Copy and paste the link below into the “Links pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link: http://www.surveymonkey.com/s/ZY5LQBD (3B) Level 1 Reaction Survey: Copy and paste the link below into the “Links pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link: http://www.surveymonkey.com/s/QZL36B5 Step 4: Close lesson and preview next module. Great job, everyone! Let’s break for lunch and return at noon for the rest of the training.


Session 6: Proper Use of Hand Tools

Overview: The purpose of this lesson is to give process operators an introduction to equipment used in common tasks at TRAC refinery, as well as instruct them on the proper use of those hand tools. Learning Objectives: Given hand tools, process operators will correctly identify each tool Given hand tools and tasks, process operators will appropriately match proper tools with matching tasks Given hand tools, process operators will demonstrate the safe and correct use of the tools

Evaluation Method: Knowledge test Identification sheet Demonstration Estimated Training Time: 2.75 hours Job Aids, Learning Aids, or References: Computer with Internet connection and Microsoft Office suite installed on it Adobe Connect meeting with files uploaded to meeting Poll questions pre-loaded in to Adobe Connect Instructor files for supplemental documents to share with group Props (wrench hand tools) Webcam Microphone Speakers Instructional Delivery: The Trainer will conduct the following steps throughout the Lesson Plan for delivery of knowledge-based training. See “notes” section of PowerPoint files for detailed verbiage for each step. Step 1: Course and Objectives Introduction - Instructor on screen speaking with slides also on screen Given hand tools, process operators will correctly identify each tool Given hand tools and tasks, process operators will appropriately match proper tools with matching tasks Given hand tools, process operators will demonstrate the safe and correct use of the tools

Step 2: Present the lesson, using the “notes” section for directions. Step 3: Demonstrate Use of Hand Tools For this demonstration, make the Adobe Connect web-cam pod of the instructor the largest part on the screen for the participants. The instructor and he participants each have a sample wrench and pipe valve in their meeting rooms. The instructor should demonstrate how-to use the two tools based on the instructions presented in the PowerPoint slides. The participants will also try to use the tools in their training rooms with the hand tools and prop valves provided.


For this demonstration, the instructor should be looking for adequate skill level and comfort in using the tools to move on to the next part of the lesson. Step 4: Briefly summarize the lesson by reviewing objectives and introduce knowledge assessment and reaction survey. (4A) Use Adobe Connect Poll pod to complete knowledge assessment. Questions are below. Encourage discussion, via chat or microphone) with each question. Poll questions should be pre-loaded into Adobe Connect. Answers bolded below.

1. Is it appropriate to use a pipe wrench in place of a valve wrench? a. No

2. Sam tried to loosen a bolt with combination wrench and it wouldn’t budge. What tool should he

try next? a. Long Handle Wrench

3. Drill pins are made of steel and spark resistant.

a. True b. False

i. They are made of steel so they are NOT spark resistant.

(4B) Hand tool identification survey – Part 1 Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the knowledge test. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

Once operators complete the first survey, copy the Part 2 survey into the Links pod as instructed above. The operators must correctly identify eight of ten items to pass. If they do not meet the requirement, they must review the material and try again. Part 1: http://www.surveymonkey.com/s/F3CFR3Z Part 2: http://www.surveymonkey.com/s/F3XJ9FB (4C) Level 1 Reaction Survey: Copy and paste the link below into the “Links” pod of Adobe Connect. Instruct process operators to click on the link appearing in the “Links” pod on the right-hand side of their screen, and complete the short reaction sheet. After they complete the reaction survey, remind the trainees to close the browser and return to the Adobe Connect session.

• Link: http://www.surveymonkey.com/s/8H5WPNN

Step 5: Wrap Up lesson


Session 7: Training Conclusion Wrap up the training by reviewing the objectives in Appendix A. Check for any questions. Congratulations – You’re on your way to meet the requirements to receive your “TRAC Introduction to Safety” certification to begin as a plant process operator. Your certificate will be e-mailed to you, your direct supervisor, and your human resources contact at your local plant. (Certificate template is in Facilitator’s files named “Completion Certificate.”) (PDF provided in files, however editable file available to trainers.) Post-Training Evaluation Three months after training concludes, conduct the level three evaluation. Each Plant Process Operator and his/her supervisor should receive the e-mail with survey link in APPENDIX D.


Appendix A

Objectives – Plant Process Operator Training Overall Identify the basic operations of an oil refinery Define workplace safety Demonstrate proper use and wearing of personal protective safety equipment (PPE) Identify hand tools and demonstrate their proper use Demonstrate the basic techniques of hazard recognition safety Demonstrate the basic techniques of fall protection safety Refining Overview Employees will score an 85% or higher on the crude oil refining basics knowledge test which includes the distillation process and molecular manipulation Introduction to Workplace Safety Define workplace safety Employees define their role in workplace safety Define why safety is important Define OSHA’s role in workplace safety PPE Identify personal protection items and their appropriate functions and applications while working in an oil refinery Demonstrate the proper way to put on, take off, adjust and wear personal protective equipment while working in an oil refinery Recall that PPE is the last line of defense against hazards Demonstrate the proper way to inspect PPE prior to use Hand Tools Given hand tools, process operators will correctly identify each tool Given hand tools and tasks, process operators will appropriately match proper tools with matching tasks Given hand tools, process operators will demonstrate the safe and correct use of the tools Hazard Recognition Identify work place hazards Define causes of work place hazards Identify unsafe actions that cause work place hazards Identify unsafe conditions that cause work place hazards Utilize five practical methods to identify, prevent and eliminate work place hazards Fall Protection & Working from Heights Overall: Identify installation, testing, and inspection requirements of safety nets Identify installation, testing, strength, and storage requirements for personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness Recognize safety requirements when working from heights in specific relation to scaffolds, hole covers, fixed ladders, and aerial lifts


Lesson 1: Safety Nets Identify accurate frequency in which safety nets must be inspected (in regards to wear, damage, or deterioration) Specify when safety nets are recommended as a fall protection option in terms of work surfaces’ height Define installation and testing conditions for safety nets Lesson 2: Personal Fall Arrest System Define minimal height requirements, inspection requirements, and maximum deceleration rates in which personal safety harnesses can be utilized in regards to fall protection Identify strength requirements for anchor points List four factors that must be considered for storage purposes of personal safety harnesses Demonstrate proper inspection and wear of a personal safety harness Lesson 3: Working from Heights Objectives Recognize safety requirements when working from heights in the following areas: Scaffolds Hole Covers Fixed Ladders Aerial Lifts


APPENDIX B

Initial E-‐Mail to Participants Dear (Fill in Name), Welcome to the TRAC Oil Refinery, and congratulation on your new role as a Plant Process Operator. Before you can begin working at the plant, you must complete a two-day web-based training session that covers vital information on safety processes, procedures, and tools you will encounter and/or use on a daily basis. We take safety very seriously at TRAC, and want you and your colleagues to go home safely at the end of each day. You are required to complete this training as the first step in your training. The requirements to continue in the program will be discussed as you go through the program. You must meet the minimum requirements of the training to receive your “TRAC Introduction to Safety” certification to begin as a plant process operator. On the dates listed below, please report to the Human Resources front desk at your TRAC plant. You will be guided to the training room where everything you’ll need with be there. Simply log in to your TRAC email account, and click on the link below to get started. This training session will be a web-based course led by a TRAC Trainer from our headquarter plant. Your training dates: Monday, April 30, 2012 at 7:30 a.m. Tuesday, May 1, 2012 at 7:30 a.m. LINK TO OPEN TRAINING SESSION: http://connect.lsu.edu/tractraining/ If you have any questions, feel free to e-mail me at this address. I look forward to meeting you on Monday, April 30, 2012. Best, Sally Trainer Hear TRAC Trainer TRAC Headquarters, Lake Charles, LA [email protected]


Appendix C

Answer Keys to Knowledge tests Basic Oil Refinery Overview: 1. A 2. C 3. B 4. C 5. A 6. D 7. B 8. A 9. C 10. D 11. B 12. B 13. C 14. A 15. D 16. Distillation 17. Coker 18. True 19. True 20. True Workplace Safety: 1. D 2. D 3. False; Correct statement should read “Employees, especially new hires, should or are encouraged speak to their co-workers about safety.” 4. D 5. True Hand Tools Part 1:

1. Hammer Wrench 2. Drift Pins 3. Brass Wedge 4. Tube Bender 5. Banana Wedge

Hand Tools Part 2:

1. Pipe Wrench 2. Long Handle Wrench 3. Tubing Cutter 4. Hammer 5. Wrenches

Hazard Recognition: 1. Planning

2. Last minute safety check 10 second drill observation Out-of-view observations Key questions of safety hazard recognition Equipment inspections 3. SLAM

4. Acts of God or nature Acceptable risks Deliberately hurting oneself 5. Inadequate guards & devices Poor housekeeping Projection & impaling hazards Congestion & close clearances Hazardous atmospheres Hazardous personal attire Inadequate fall protection Improper placement & storage Poor illumination & loud noises Unidentified chemicals 6. Operating equipment without authority Failure to make secure Operating at an unsafe speed Overriding safety devices Using defective tools and equipment Taking an unsafe position Horseplay Being in the line of fire Not keeping eyes on the task Taking shortcuts Failure to warn or signal 7. Work Permit

8. Planning (prior to exposure) Auditing (during exposure) Incident Investigation and review (post exposure)



APPENDIX D

Follow Up Evaluation E-‐Mail to Participants & Supervisors Facilitator: Send the appropriate e-mail to the participant and the participant’s supervisor three months after training completion. Dear (Participant), I hope you are enjoying your new role as a Plant Process Operator with TRAC Oil Refinery. Three months ago you completed the “TRAC Introduction to Safety” certification process. To gauge the extent to which you have transferred knowledge obtained in the Plant Process Operator (PPO) course to on-the-job performance, please complete this brief ten-minute survey. Please note this survey seeks to evaluate the effectiveness of the training program, and responses will be utilized to improve future training programs. Ensuring confidentiality of participants' responses is of upmost importance. To uphold confidentiality, please do not provide answers within the short-answer section that may potentially identify yourself. We appreciate your honest feedback and time spent completing this survey. Survey link: http://www.surveymonkey.com/s/QR8TMHN If you have any questions, feel free to e-mail me at this address. Best, Sally Trainer Hear TRAC Trainer TRAC Headquarters, Lake Charles, LA [email protected]


Follow Up Evaluation E-‐Mail to Participants & Supervisors Facilitator: Send the appropriate e-mail to the participant and the participant’s supervisor three months after training completion. Dear (Participant’s Supervisor), Three months ago at least one of your direct reports completed the “TRAC Introduction to Safety” certification process. To gauge the extent to which knowledge transferred obtained in the Plant Process Operator (PPO) course to on-the-job performance, please complete this brief ten-minute survey. Please note this survey seeks to evaluate the effectiveness of the training program, and responses will be utilized to improve future training programs. Ensuring confidentiality of participants' responses is of upmost importance. To uphold confidentiality, please do not provide answers within the short-answer section that may potentially identify yourself or your PPO. We appreciate your honest feedback and time spent completing this survey: http://www.surveymonkey.com/s/Q7WPZBP If you have any questions, feel free to e-mail me at this address. Best, Sally Trainer Hear TRAC Trainer TRAC Headquarters, Lake Charles, LA [email protected]

Documents

TRAC Facilitator's Guide