Process Technology Operations

This textbook was written for an operations course within a process technology associate's degree program. Industry may also find it a useful tool for training process technicians. Chemical process operators have been taken for granted for many years. The general opinion in the chemical process industry has always been that any high school graduate can fill their operator needs. This opinion started to change in the mid-1990s, as the industry faced many new situations. Pneumatic and electronic process controllers have been replaced by computer control systems that not only control the processes better, but also collect comprehensive information about the process and store it in easily accessed databases. Process systems and equipment have become more complex and sophisticated, and neural networks and other logic systems have been used to provide predictive control of operations. In addition, state and federal regulatory groups such as OSHA and the EPA have issued regulations that must be followed by process operators, and quality certification programs such as ISO 9000 have placed new demands on them. The job is no longer simply an operator's job; it requires a well-trained technician. The need for well-trained employees has already been recognized in Canada, where standard curriculum has been developed and certificate or licensing programs are in place. In the United States, the Gulf Coast Process Technology Alliance has led the way, and process technology associate's degree programs are becoming popular in many community colleges. The process technology program associate's degree course at Victoria College started in the mid-1990s. One of the biggest challenges that we faced as we started this program was a lack of textbooks from which to teach. This book was written to fill that need for updated training materials and information, using the subject matter and curriculum guidelines developed by the Gulf Coast Process Technology Alliance as a guide. The book focuses on the duties of a process technician. The routine, day-to-day requirements of various jobs that a technician may be required to handle, stressing the importance of communication, teamwork, problem solving, and diversity, are all covered in detail. It also addresses the nonroutine aspects of the job, including experimental operations directed by a research or technical program, emergency situations that require quick, logical responses from the technician, and unit start-ups, shutdowns, and turnarounds that are needed to keep any plant running efficiently. We have built on the information and experience we gained from teaching courses that address process equipment, process health, safety, environmental concerns, and chemical process systems. The process operations course for which this textbook has been written is designed to complete the education of process technicians so that they are prepared to enter industry with the necessary training and skills to become valuable employees. ACKNOWLEDGMENTS Special thanks to Al J. Dworsky, Equistar Chemicals, LP, and Ronnie Baker, Lamar Institute of Technology, for their insightful review of the manuscript. James E. FeigFeig, James E. is the author of 'Process Technology Operations' with ISBN 9780130279309 and ISBN 0130279307.