CHEMICAL PROCESS OPERATIONS NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR CHEMICAL PROCESS OPERATIONS NC III

The TESDA Course in CHEMICAL PROCESS OPERATIONS NC III consists of competencies that a person must achieve to perform chemical operations and control chemical processes.

A student who has achieved this TESDA Course in CHEMICAL PROCESS OPERATIONS NC III is competent to be:

• Chemical Process Operator

CHEMICAL PROCESS OPERATIONS NC III – TRAINING AND REGULATION MODULE

Course Title: CHEMICAL PROCESS OPERATIONS
Level: NC III
Nominal Training Duration :

Basic Competencies – 20 Hours
Common Competencies – 56 Hours
Core Competencies – 224 Hours

TOTAL DURATION: 300 Hours

This course is designed to enhance the knowledge, skills and attitude of CHEMICAL PROCESS OERATIONS NC III in accordance with industry standards. This covers competencies that a person must achieve to perform chemical operations and control chemical processes.

TRAINEE ENTRY REQUIREMENTS

Trainees or students wishing to gain entry into this course should possess the following requirements:

• Must have completed 12 years basic education
• Can communicate in English language both oral and written
• Must be physically fit

COMPETENCIES REQUIRED IN CHEMICAL PROCESS OPERATIONS NC III

This units of competency comprising this qualification include Basic, Common, Elective and Core Competencies.

To obtain this TESDA Course in CHEMICAL PROCESS OPERATIONS NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (224 hours)
CPP313301	Determine process requirements
CPP313302	Evaluate process data
CPP313303	Operate process equipment
CPP313304	Monitor process equipment
CPP313305	Qualify in-process and finished product samples
CPP313306	Perform shutdown activities
UNIT CODE	COMMON COMPETENCIES (56 hours)
CPP313201	Observe safe working practices
CPP313202	Comply with emergency procedures
ELC724201	Use hand and measuring tools
ELC311201	Perform mensuration and calculation
CPP313203	Apply quality standards
UNIT CODE	BASIC COMPETENCIES (20 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

These guidelines are set to provide the Technical Vocational Education and Training (TVET) providers with information and other important requirements to consider when designing training programs for CHEMICAL PROCESS OPERATIONS NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : DETERMINE PROCESS REQUIREMENTS
UNIT CODE : CPP313301

This unit covers the knowledge, skills and attitudes in determining raw materials, verifying material specifications and identifying equipment and utilities for chemical processing.

1. Determine raw materials
   • Raw materials are identified in accordance with production plan.
   • Coordination with personnel or other departments is completed where necessary.
   • Documentation is prepared in accordance with enterprise requirements.
2. Verify material specifications
   • Raw materials are retrieved or received in accordance with established company procedures.
   • Quality and quantity of materials needed are checked and qualified.
   • Non-conforming materials are identified.
   • Actions are taken to address non-conformances.
   • Readiness of materials is reported in accordance with company requirements.
3. Identify equipment and utilities
   • Equipment are identified in accordance with production plan.
   • Utilities are identified in accordance with production.
   • Equipment and utilities are verified to be in good operating condition.

UNIT OF COMPETENCY : EVALUATE PROCESS DATA
UNIT CODE : CPP 313302

This unit covers the knowledge, skills and attitudes in collecting and verifying process data and doing process adjustments.

1. Collect process data
   • Process parameters and standard settings are identified in accordance with product formulations.
   • Process parameters are generated and read/taken and recorded in accordance with established company procedures.
   • Safety procedures are practiced.
2. Verify process data
   • Actual process parameters are compared against the standard parameters in accordance with established procedures.
   • Interpreted results are recorded and reported to immediate supervisor in accordance with
3. Make adjustments
   • Process variations are identified in accordance with established company procedures.
   • Troubleshooting is taken in accordance with established procedures.
   • Safety procedures are practiced.
4. Recommend process improvement
   • Process Records are reviewed
   • Process improvement is proposed.

UNIT OF COMPETENCY : OPERATE PROCESS EQUIPMENT
UNIT CODE : CPP313303

This unit covers the knowledge, skills and attitudes in conducting ready-for-start-up and starting up equipment and practicing occupational health, safety and environmental protocols.

1. Conduct ready-forstart-up activities
   • Process Equipment is identified in accordance with job requirements and the manufacturer’s specifications.
   • Process Equipment are inspected in accordance with the established procedures.
   • Where necessary, needed corrections are made to ensure readiness of process equipment in accordance with established procedures
   • Documentation in relation to ready-for-start-up activities is forwarded to appropriate personnel in accordance with company requirements.
2. Start-up equipment
   • All Equipment are started up in accordance with manufacturer’s specifications and operations manual.
   • Required control rate is built and maintained in accordance with established requirements.
3. Occupational health and safety protocols are practiced
   • Engineering controls are installed and in good working condition
   • Administrative controls are documented and implemented.
   • Appropriate Personal Protective Equipment is used.
4. Environmental protocols are implemented
   • Wastes are managed accordingly
   • Emissions and discharges are within regulatory limit.

UNIT OF COMPETENCY : MONITOR PROCESS EQUIPMENT
UNIT CODE : CPP313304

This unit covers the knowledge, skills and attitudes in verifying operating parameters, adjusting equipment settings and updating operating records of process equipment

1. Verify operating parameters.
   • Routine checks of process equipment conditions during operation are performed and completed in accordance with the established procedures.
   • Indications of potential and actual equipment problems are recognized and immediately reported in accordance with the established procedures.
   • Documentation is prepared and forwarded immediately to appropriate personnel and/or authority in accordance with company requirements.
   • Safety protocols are practiced.
2. Adjust equipment setting.
   • Manual/electronic adjustments and actions are done to address indications of potential and actual equipment problems in accordance with the established procedures.
   • Manual/electronic adjustments done are recorded and reported to immediate supervisor in accordance with the established procedures.
   • Safety protocols are practiced.
3. Update data sheets.
   • Required production data sheet is prepared in accordance with established procedures.
   • Production Data sheet is filled up in accordance with established procedures.
   • Data sheet is regularly accomplished in a timely, truthful and accurate manner.

UNIT OF COMPETENCY : QUALIFY IN-PROCESS AND FINISHED PRODUCT SAMPLES
UNIT CODE : CPP313305

This unit covers the knowledge, skills and attitudes collecting samples in chemical processing plant, verifying its conformance and documenting the findings.

1. Collect samples
   • Sampling requirements are secured in accordance with sampling plan.
   • Safety Personal Protective Equipment is worn in accordance with established procedures.
   • Samples are taken in accordance with established procedures.
   • Samples are labeled properly and turned over to appropriate personnel in accordance with established procedures.
2. Verify conformance
   • Results of quality control tests are retrieved or received in accordance with established procedures.
   • Actual results are compared against standard product and process specifications in accordance with established procedures.
   • Non-conforming samples are identified in accordance with established procedures.
   • Actions are taken to address non-conformances in accordance with established procedures.
3. Document findings
   • Required data sheet is prepared in accordance with established procedures. Reports are prepared and maintained in accordance with established procedures.

UNIT OF COMPETENCY : PERFORM SHUTDOWN ACTIVITIES
UNIT CODE : CPP313306

This unit covers the knowledge, skills and attitudes in preparing to shut down and shutting down process equipment

1. Prepare for shutdown
   • Requirements are complied with in accordance with established procedures.
   • Proper coordination is done with appropriate personnel in accordance with the established procedures.
   • Final inspection is conducted to ensure proper sequence and safety of shutdown in accordance with the established procedures.
2. Shutdown process equipment
   • Equipment is properly shut down in accordance with the established procedures for scheduled and emergency shutdowns.
   • Shutdown record is prepared and forwarded immediately to appropriate personnel in accordance with company requirements.
   • Safety protocol is practiced.

COMMON COMPETENCIES

UNIT OF COMPETENCY : OBSERVE SAFE WORKING PRACTICES
UNIT CODE : CPP313201

This unit deals with the knowledge and skills required to Identify and follow workplace procedures for hazard identification and risk control; Contribute to arrangements for the management of occupational health and safety; and complete Occupational Safety and Health (OSH) records.

1. Identify and follow workplace procedures for hazard identification and risk control
   • Safety regulations and company established safety and hazard control practices and procedures are obtained, interpreted and applied to day-to-day work activities
   • Workplace procedures for Occupational Health and Safety and related work instructions for controlling risks are accurately followed
   • Workplace procedures for dealing with accidents, fire and emergencies are known and followed
   • Hazards in the workplace are identified and appropriate action is taken to report them and to minimize or eliminate risk to personnel.
2. Contribute to arrangements for the management of occupational health and safety
   • Occupational health and safety committee meetings are attended.
   • Safety and environmental issues are discussed to the Health and Safety committee meetings or other venues in accordance to the company procedures.
   • Safety audits or inspections are conducted in accordance with the company procedures.
   • Occupational Health and Safety Rules or Standards are understood and complied.
   • The role of workers in the health and safety committee is understood.
3. Complete occupational health and safety records
   • Occupational health and safety records for self are completed in accordance with workplace requirements.
   • Legal requirements for the maintenance of records of occupational injury and diseases are followed.

UNIT OF COMPETENCY : COMPLY WITH EMERGENCY PROCEDURES
UNIT CODE : CPP313202

This unit deals with knowledge and skills required to take actions to prevent occurrence of emergency, follow established protocols to control or manage risks in the workplace and take appropriate actions to control the emergency.

1. Take actions to prevent occurrence of emergency.
   • Hazards and risks assessment is conducted to prior to application of new processes/ materials/ equipment in the workplace.
   • Emergency practice drills are performed where practicable.
   • Training is conducted for proper use of emergency equipment.
   • Unsafe acts and conditions are reported and corrected immediately.
   • Emergency communications and alarm signals and systems are understood and required action implemented in accordance with emergency procedures.
2. Follow established protocols to control or manage risks in the workplace
   • Critical areas or processes are identified.
   • The safety protocols are strictly followed in accordance with the procedure of the company.
   • Work permit system of the company are being complied.
   • Operational controls are in placed before starting work.
3. Take appropriate actions to control the emergency
   • Emergency situations are correctly recognized and identified.
   • Information given on raising alarm is prompt, accurate, complete and clear.
   • Appropriate response is taken in accordance with established company procedures.
   • Contingency plans for emergency response are known and are implemented in real and simulated emergency situations
   • Evacuation routes and internal and external communications and alarm systems are correctly used in real and simulated emergency situations in accordance with regulatory requirements and established procedures.

UNIT OF COMPETENCY : USE HAND AND MEASURING TOOLS
UNIT CODE : ELC724201

This unit covers the knowledge, skills and attitudes in preparing, using and maintaining hand and measuring tools.

1. Prepare the required tools corresponding to tasks to be undertaken
   • Tasks to be undertaken are properly identified
   • Appropriate measuring tools are identified and selected according to the task requirements
2. Use appropriate hand tools and test equipment
   • Appropriate hand tools are checked for proper operation and safety
   • Unsafe or faulty tools are identified and marked for repair according to standard company procedure
   • Tools are used according to tasks undertaken
   • All safety procedures in using tools are observed at all times and appropriate personal protective equipment (PPE) are used
   • Malfunctions, unplanned or unusual events are reported to the supervisor.
3. Maintain hand tools
   • Tools are not dropped to avoid damage
   • Routine maintenance of tools undertaken according to standard operational procedures, principles and techniques
   • Tools are stored safely in appropriate locations in accordance with manufacturer’s specifications or standard operating procedures

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATION
UNIT CODE : ELC311201

This unit covers the knowledge, skills, attitudes and values needed in the selection and maintenance of measuring instruments and carrying out measurements and calculations.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Measuring tools are selected in line with job requirements
2. Carry out measurements and calculation
   • Appropriate measuring instrument is selected to achieve required outcome
   • Accurate measurements are obtained for job
   • Calculation needed to complete work tasks are performed using the four basic process of addition (+), subtraction (-), multiplication (x), and division (/)
   • Calculation involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.
   • Proper storage of instruments undertaken according to manufacturer’s specifications and standard operating procedures.

UNIT TITLE : APPLY QUALITY STANDARDS
UNIT CODE : CPP313203

This unit covers the knowledge, skills, attitudes and values to assess quality of own work and engage in quality improvement.

1. Assess quality of own work
   • Required documentation within the company is identified.
   • Completed work is checked against workplace standards.
   • Errors are identified and isolated.
   • Analysis of errors including actions taken to eliminate it are documented and reported in accordance with the workplace’ s standards operating procedures.
2. Engage in quality improvement
   • Work is carried out in accordance with the company’s management system.
   • Performance are regularly monitored in accordance with the established company procedures.
   • Continual improvement programs are in place in accordance with the established company procedures.

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action

DEFINITION OF TERMS

• Process – An action or series of actions, changes, or functions that converts input into output. A process may require many unit operations to obtain the desired product from the starting materials, or feedstocks.
• Unit operation – Is a basic step in a process. Unit operations involve a physical change or chemical transformation such as separation, crystallization, evaporation, filtration, polymerization, isomerization, and other reactions. For example, in milk processing, homogenization, pasteurization, chilling, and packaging are each unit operations which are connected to create the overall process
• Process Control – A mechanism for maintaining the output of a specific process within a desired range.
• Requirements – Need or expectation that is stated, generally implied or obligatory
• In-process sample – Refers to samples taken during chemical processing stages. Test Results or Data from in-process samples are used in order to prevent off-specs finished product.
• Final Sample – Refers to samples taken from the desired product at the end of the process in order to identify defects in the finished product.