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350-Bsp - 0157 - Proced Oper Training Final Predat Dec.2018
350-Bsp - 0157 - Proced Oper Training Final Predat Dec.2018
Project manager
Gheorghe
0 November 2018 Initially Bucătaru
Gheorghe Pasăre Simion Manea
NO. DOCUMENT
REV. DATE DESIGNED CHECKED APPROVED
DESCRIPTION
Revision Sheet
CUSTOMER:
MINISTRY OF ELECTRICITY (MOE)
REPUBLIC OF IRAQ
PROJECT :
IFB no. M21-21-2016
Rehabilitation of Unit 3
Facilities and Common System, Al Mussaib Thermal Power Plant Rehabilitation
CONTRACTOR:
DESIGNED BY DATE
TITLE:
Gheorghe Bucătaru November 2018
OPERATIONAL PROCEDURE
CHECKED BY DATE Planning and conducting the training procedure
Gheorghe Pasăre November 2018 for Customer’s speciality operating staff
APPROVED BY DATE
WASTE WATER TREATMENT PLANT
No DESCRIPTION PAGE
1. PURPOSE 3
Page 2 of 20
1. PURPOSE
A central challenge and requirement for ensuring the safety and reliability
of Waste Water Treatment Plant (WWTP) is to attain and maintain the
qualification and competence of plant (WWPT) personnel, which includes
operations, maintenance, management and technical support personnel.
• to define the conditions for the safe conduct of the training and the
subsequent operation of the WWTP ‘s facilities,
• As well as to determine the concrete conditions regarding who is
participating in the training,
• How the training program is being carried out,
• What are the facilities necessary to run the training program and
who provides them.
Page 3 of 20
2. TRAINING METHOD and JOB STRUCTURE OF
TRAINEES
2.1 TRAINING METHOD
TRAINING can be formal (in official schools) informal (at work place for
example) and non formal (any individual way the trainee choose). This is a
combination of informal and Nonformal training.
Experience has shown that, to attain professional competence, The
Training Program (Training Procedure application) should comprise training to
achieve both the necessary technical and human factors competencies.
Thus, BSP Commisioning Team’s Training Procedure (BSPCTTP)
emphasizes a broader concept of competence which includes not only technical
knowledge and skills but also knowledge, skills and attitudes related to human
factors. In addition to the training of operating personnel, the BSPCTTP deals
with the role and responsibilities of :
o management (coordinators and WWTP heads);
o shifts leaders and maintenance personnel;
o auxiliary / support pesonell involved in WWTP operation
Page 4 of 20
2.2 JOB STRUCTURE OF TRAINEES
In order to start and complete the Training Program for WWTP operating staff Beneficiary
should, however, to choose and nominate its champions according to more than just their job
position.
In choosing the Beneficiary’s staff to participate to the training program it is advisable
Beneficiary’s responsible leaders probably thinking of certain people who carry some authority
among their operating staff and shall be later on responsible for the WWTP operation in years to
come.
All trainees nominated by the Beneficiary to attend / participate in the Training Program
conducted according to BSP Commisioning Team’s Training Procedure should participate / attend
/ witness the Commissioning activities.
Trainees nomination (done by Beneficiary) should cover the following job
specialities:
Shift
Other WWTP supervisors
personnel
Electricians Instrumentation
(MCC + field
electric motors, specialists
transformers, (control panels + field
Invertors, etc) instrumentation)
Mechanical works
PLC – HMI intervention
specialists specialists
Page 5 of 20
The Training Program has a modular structure; Some Training Modules are compulsory for
all trainees / learners, regardless of their specialization, others are specifically addressed to
certain specializations but even these may also be of interest to other specialties; That is
why trainees are encouraged to participate in all training Modules even if some modules
can be considered outside of their field of interest / specialization.
The training course / training program addresses the operating personnel who will work in
the WWTP and therefore it does not address top management (Plant Manager, Process
Engineer for WWTP etc.). However, any person from the Leadership, if they wish, can
optionally participate in the Training Program and they are welcome (especially as the
training method used in this Training Program is one such as ”Training the Trainers”)
Page 6 of 20
3. TRAINING SCHEDULE and TRAINING MODULES
OVERVIEW
3.1 SCHEDULING THE TRAINING
Mainly the Training of the Beneficiary’s operating staff (who will
eventually take over the Waste Water Treatment Plant(WWTP) for continuous
long lasting operation) is one of the principal activitiy within the complex
Commissioning Process. As long as the Beneficiary’s operating staff it is
advisable to be present and witness on site the Contractor's Commissioning
Team activities during the entire period of testing, inspection, verification and
adjustment, trial works etc. done within the commissioning process / work, The
Training Process shall normally be a continuos one during the whole
Commissioning Process.
INFORMAL TRAINING
OPERATORS
RELIABILITY TEST
The sequences are quite in a logical normal order (succession) and only a
few, at the and of the process can be performed in reverse order if required.
Page 8 of 20
However, timing of sequences is not always done one after the other, there
may be overlapping, gaps, stagnation etc. as the real situations from the site
request.
The checking and testing phases of a new Waste Water Treatment Plant is
by necessity a relatively detailed and sophisticated process.
Not all parts of the WWT plant (e.g. Abnormal Waste Water Treatment
Section, Normal Waste Water Treatmen Section or Oily Water Treatment
Section) reach the same degree of completion at the same time, hence some
areas or Sections / units may be mechanically completed while others are not.
It would therefore be a waste of time to wait for the whole WWT plant to be
mechanically completed before starting commissioning activities.
Page 9 of 20
Therefore, the Commissioning planning shall be optimised if the completion
activities are organised not as whole WWTplant activities, but by Operational
Systems and Subsystems
Systems/Sub-systems definition
This specific partition of WWT plant into systems and subsystems for
completions activities takes place as early as possible, prior to Commissioning
Process implementation.
The partition of WWT plant is a key preparation activity for Commissioning
and implicitly to facilitate the structuring of the Beneficiary’s Operators
Training Course into Modules, that has a major impact on all aspects of
completion operation.
The subsystems must be defined so as to be as independent as possible,
not too small, but of manageable size, and exactly adapted to the Start-Up
sequence.
The number of Sub-systems should not ideally be more than 500, but will
depend on the size of the WWTP.
Page 10 of 20
The basic principle of the completion activities will be to:
• Define, organise, prepare, carry out, report all Precommissioning
and Commissioning activities by systems and subsystems
• The completion activities progress will be reported with a partial
overlapping between systems and subsystems, according to the
Start-up sequence
COMMISS
INITIAL
OPERATION
ROUTINE OPERATIO
Job Shadowing
INFORMAL TRAINING Effective On-the-Job Training
THEORY HANDS ON
Shadowing BSP
CLASSES CLASSES Commissioning Team
3 hours
THEORY CLASSES / day
Trainees
evaluation
4 hours
and
certification
There is no specific schedule for informal training. There is valid only the
main schedule for Commissioning activities.The Beneficiary’s operators can
benefit from an informal training through their mere voluntary presence on the
site while BSP Commissioning Team is conducting Commissioning, assisting
BSP's commissioning teams members. Trainees / operators can participate
effective in activities during Reliability tests when they can get responsibilities on
operating the installation
The commissioning activities during the functional tests are full time activities and
run in shifts covering 24h.
In this period of Informal Training the trainees are doing Job Shadowing.
Page 12 of 20
Job shadowing allows the observer to see and understand the nuances of
a particular job. The job shadowing employee is able to observe how the
specialist does the job, the key deliverables expected from the job, and the
employees with whom the job interacts.
Job shadowing can provide enough information about the new and different
job to allay the employee's fear of the unknown. So, job shadowing is a handy
tool when you want employees to have lateral moves in new commissioned
plants (e.g. WWTP)
While all jobs can have a component of job shadowing as part of their
training and employee development plan, job shadowing is especially effective
for jobs such as these needed in WWTP long term operation.
Page 13 of 20
3.2 TRAINING MODULES OVERVIEW
▪ Safety
MODULE 1 3h theory
▪ Commissioning
To all
Topics: Process
specialities
6h 3h l
Safty&Commissining ▪ Main operations on Hands on
WWTP overview
▪ comprehension of
MODULE 2 waste water treatment 2h theory
Topics: system To all
▪ functional description specialities
6h 2h l
waste water treatment Hands on
system description
▪ Component Systems
overview
- System overview
2h theory
- Normal Waste Water
Pond
- Normal Waste Water
Pumps
- Reaction Tank
- Coagulation Tank
- Clarifier
MODULE 3 - Clarified Water Pond
To all 2h l
Topics: - Thickener
- Dehydrator specialities 4h Hands
Normal Waste Water - Pressure Filters
on
Practical
Treatment System - Activated Carbon Filters on site
- Filtered Water Storage
Tank
- Filter Back Washing
Pump
- Treated Water Pond
- Effluent Pond
- Effluent pump
Page 14 of 20
Module content Adress hours Classes
- System overview
- Waste Water Holding
MODULE 4 Pond 2h theory
- H2SO4 Tank and acid
Topics: injection systems
To all
-NaOH Tank and NaOH 4h 2h l
Abnormal Waste injection systems specialities
Hands on
Water Treatment - A-Polymer Tank and Hands on
System injection systems Practical
- C- Polymer Tank and on site
injection Systems
- System overview
1h theory
MODULE 5 - Oily Waste Water Pond
- Oil Separator
Topics: - Oily Waste Water Pumps To all 1h l
- Scum Tank (W-006.4.9) specialities 2h Hands on
Oily Waste Water - about reduction of oil Practical
Treatment System contents to 10 mg/l on site
maximum
- Electrical supply
system overview
- Utility systems 6h theory
overview
- Instrument air
- service air
- service water
- electrical power
MODULE 6 - MCC
Topics: - Local control panels
- Inverters
Mainly to
electricians 10h
Utility & MCC - No load tests for 4h l
electric motors Hands on
- Load and run tests for Practical
electric motors on site
- Earthing
- On site illumination
- Maintenance and
troubleshooting on
electric systems /
circuits
Page 15 of 20
Module content Adress hours Classes
-General Control Panel
overview
operators
-electrical systems
Instrumentation,
upstream and downstream
of the motor control center
10h 4h l
Control Panels, PLC -Panel mounted Hands on
&HMI instrumentation Practical
-Field mounted on site
instrumentation
-PLC I/O signals
-PLC – HMI comunication
-Operations conducted
from HMI
-Settings and calibration of
Instruments
Evaluation and
Quizzes & answers 4h
Certification
Page 16 of 20
4. RECORDS for APPLICATION OF THE
TRAINING PROCEDURE
4.1 List of nominated trainees
List of selected (issued by Beneficiay) operational staff to participate to the
Training Program:
Available hours /
Trainee
No.crt Speciality / job position Nominalization day for attending
commitment
training Program
Shift
1.
supervisors
Add as many rows as you consider necessary to fit your selection for personnel to be trained
Control room
2.
operators
Add as many rows as you consider necessary to fit your selection for personnel to be trained
3. Field operators
Add as many rows as you consider necessary to fit your selection for personnel to be trained
Electricians
4. (MCC + field electric motors,
transformers, Invertors, etc)
Add as many rows as you consider necessary to fit your selection for personnel to be trained
5. Instrumentation
specialists
(control panels + field
instrumentation)
Add as many rows as you consider necessary to fit your selection for personnel to be trained
Page 17 of 20
Maintenance
6. personnel chief
in charge
Add as many rows as you consider necessary to fit your selection for personnel to be trained
7.
PLC – HMI
specialists
Add as many rows as you consider necessary to fit your selection for personnel to be trained
Mechanics
8. Mechanical works
intervention specialists
Add as many rows as you consider necessary to fit your selection for personnel to be trained
9.
Other WWTP
personnel
Add as many rows as you consider necessary to fit your selection for personnel to be trained
Shift
Other WWTP supervisors
personnel
Electricians Instrumentation
(MCC + field electric
motors,
specialists
transformers, (control panels + field
Invertors, etc) instrumentation)
Mechanical works
PLC – HMI intervention
specialists specialists
Page 18 of 20
4.2 PRESENCE LIST
Every training session should have a Presence List to track the trainees
participation in the Training Program
Add as many rows as you consider necessary to fit your trainees number
Page 19 of 20
4.3 FINAL CERTIFICATE ISSUED FOR ALL PARTICIPANTS
IN TRAINING PROGRAM
Page 20 of 20