The Process TechnicianThe Process Technician

Introduction to Process TechnologyPTAC 1302

WCJC – Fall 2014

TopicsTopics

• Where Do They Work?• Job Outlook• What They Do (Roles)• Responsibilities• Qualifications – knowledge and skills, interpersonal

skills, education• Physical Capabilities Needed• Mental Capabilities Needed• The Shiftwork Life• Workforce Organization• Future Trends

Where Do They Work?Where Do They Work?

Process Industry

Pharmaceuticals

Pipeline

Chemical Refining Food/Bev Pulp/Paper

OilfieldEnergy

Traditional Nuclear

Alternative

Job OutlookJob Outlook

• Over 500,000 operators and 250,000 lab techs in U S

• Although sub-sectors of the process industry can be very cyclical – meaning business can boom, then crash the forecast for jobs into the future is bright– Baby Boomers Retiring– Alternative/Green industries emerging– Careers beyond control room – research,

sales, support jobs

Job OulookJob Oulook

• Wages some of the highest – “Gold” Collar– Petrochem – finishing entry $12.00– Petrochem – manuf entry $22.00 -

$28.00– Nuclear – entry $31.00 - $50.00

• Benefits

Job OutlookJob Outlook

• There is the threat of companies continuing to move operations and JOBS out of the U.S. due to– Rising labor costs– Oppressive federal and state

regulation– Raw material needs– Transportation costs as global

markets shift

Job OutlookJob Outlook

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

www.monster.com

What they doWhat they do

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

…………………….for.for

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

…………..How..How

• Safely• Efficiently• Environmentally compliant• While working as a member of a

team• With a focus on the business goals• In all types of weather………...

Summary of Summary of ResponsibilitiesResponsibilities

• Monitor and control process (more)• Minor maintenance, troubleshoot and

problem solve (more)• Administrative activities• Perform with a focus on Safety, Health,

Environment and Production• Practice quality• Training/certification and continually

learning

Monitor and Control Monitor and Control ProcessProcess

• Sample and process streams• Inspect equipment• Start, stop, and regulate equipment• Respond to changes• Respond to emergencies or abnormal

operations• Document activities, issues, and

changes

Perform MaintenancePerform Maintenance

• Change or clean filters and strainers

• Prepare equipment for repair• Lubricate equipment• Monitor equipment performance• Vibration and temperature

analysis

Troubleshoot and Problem Troubleshoot and Problem SolveSolve

• Apply root cause analysis• Participate in corrective action teams• Statistical Process Control (SPC)

QualificationsQualifications

1. Basic Skills2. Technical knowledge and skills3. Interpersonal skills4. Physical capabilities5. Mental capabilities6. Education

Basic SkillsBasic Skills

• Reading• Writing• Listening• Interpersonal Skills &

Communication• Computer Technology• Math• Science

Basic SkillsBasic Skills

• Punctuality• Multitasking• Problem Solving• Safety Awareness and Action• Quality Awareneess and Action• Environmental Awareness and

Action

Technical Knowledge, Skills,Technical Knowledge, Skills, and Abilities and Abilities

• Math. Science, Computers• Operation, maintenance, and

troubleshooting of process equipment• Key regulatory standards and laws• Communications skills: reading and

writing, industry-related materials

Qualifications:Qualifications:Interpersonal SkillsInterpersonal Skills

• Communicate effectively - reading, writing, listening

• Positive attitude towards job, others, self• Respect for safety of self and others• Maintain composure in high stress situations• Responsible• Reliable – punctual and good attendance• Appreciation for diversity• Provide and respond to feedback positively

Physical CapabilitiesPhysical Capabilities

Ability to• Work in high noise level areas [above 85 dB]• Lift, climb stand for long periods of time• Work at elevated heights• Wear personal protective equipment (PPE ]• Perform in all types of weather - heat, cold,

rain• Handle demands of shift work• Perform under pressure / high stress situations• Perform physically demanding tasks

Mental CapabilitiesMental Capabilities

• Analytical• Can process technical information

correctly and quickly if needed• Critical thinking• Problem solving• Can tolerate longs hours and

flexing work hours (nights)

EducationEducation

• Some areas – HS diploma or even GED– High school courses, college credit options

• Two-year Associates Degree in Process Technology preferred - REQUIRED by MANY AREA EMPLOYERS

• Math, Science, English• Computer skills: spreadsheets, word

processing, database applications• Continuing Education – be a lifelong learner

Work EnvironmentWork Environment

• Get to work and work regardless of weather

• Usually start outside• Work outside during turnarounds

and upsets• Inside – control room, lab

The Shiftwork LifeThe Shiftwork Life

• Not usually your “8 to 5” job• Most plants are on rotating 12 hr

shifts• Even longer days during

turnarounds, new unit/equipment start-ups

Impact on Shift WorkersImpact on Shift Workers

• Fatigue - Biological time clock is like permanent jetlag

• Reduced attention span• Reaction time slowed• Body clock and work schedule

conflict• Non-traditional life outside of

work

Potential Impacts of Shift Potential Impacts of Shift WorkWork

• Physical Health • Emotional Health• Family Problems

Taking Care of YourselfTaking Care of Yourself

• Establish as regular a schedule as possible

• Create a day-sleeping environment • Take naps when possible• Compensate for lower awareness• Only light snacks in the 2-6 am/pm

period• Avoid stimulants, alcohol, caffeine

Union/Non-UnionUnion/Non-Union

• Collective Bargaining

Future TrendsFuture Trends

• Continued emphasis on preventive maintenance of equipment

• Broader span of duties – example distribution functions, lab analysis

• More involvement in process control and business decisions

• More computerization and automation• Continuous upgrading of skills and

knowledge

Review QuestionsReview Questions

• Page 40 – Introduction to Process Technology (Thomas – 2010)