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CPTC Capability Statement_Competence Based Training in CPTC_R8_20100604
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Training Services
Chemical Process Technology Centre
Singapore
Competence Based Operations & Maintenance Training & Assessment
for the Oil, Gas and Petrochemical
Chemical Process Technology Centre
Operations & Maintenance
for the Oil, Gas and Petrochemical Industries
Chemical Process Technology Centre
Competence Based Training & Assessment Chemical Process Technology Centre
Chemical Process Technology Centre
Located in the heart of Jurong Island, Singapore, the Chemical Process
Technology Centre (CPTC) provides Competence Based Training focusing on the
skills development and assessment of operations and maintenance personnel
for the oil, gas and petrochemical industries.
CPTC provides:
• New entrants to the oil, gas and petrochemical industries with a set of
competencies by the provision of world class competence based training
and assessment, this training is open to local Singaporean and overseas
clients;
• Opportunities for working professionals in the industry to upgrade and
enhance their knowledge and skills with the latest industry technologies
developments;
• A strategic international training infrastructure aimed at developing
specialist manpower to support the growth of the global oil, gas and
petrochemical industries.
CPTC is owned by the Singapore
Economic Development Board (EDB)
and managed by Petrofac Training
Services, the training arm of the
Petrofac Group. CPTC is also a fully
accredited Continuing Education
Training (CET) Centre by the
Singapore Workforce Development
Agency (WDA).
CPTC is the first training centre in the world to contain an industry-scale
petrochemical process plant. Designed to operate as an actual production unit
in a typical commercial plant, the process unit will allow trainees to experience
real plant operations to enhance their training experience under safe and
controlled conditions.
Competence Based Training & Assessment Chemical Process Technology Centre
CPTC’s Expertise
CPTC demonstrates Singapore’s and Petrofac Training Services’ commitment to
building and enhancing a world-class workforce.
CPTC’s trainers are specialists with years of industry experience in operations,
maintenance and safety; while the teaching laboratories house state-of-the-art
equipment constantly upgraded to suit requirements of the industry.
Process Technicians working in a
chemical process plant are often
required to do specialised tasks
such as climbing vertical ladders,
operating block valves and
distributed control systems. CPTC’s
trainers impart their expertise and
experience to ensure trainees are
able to perform competently as
such. One of the option companies
tapped on, is engaging our trainers’
expertise to conduct Aptitude
Screening Tests in their pre-employment screening process, to gauge the
suitability of their job applicants to work in a process plant environment.
In addition to live-plant training, CPTC also conducts specialised courses for
working professionals in the oil, gas and petrochemical industries. They
include:
• Distributed Control System
• Process Measurement and Control
• Rotating Equipment
• Critical Incident Management
• Emergency Response and Crisis Management
• Health, Safety and Environmental
Competence Based Training & Assessment Chemical Process Technology Centre
CPTC worked closely in partnerships with our clients to allow customisation in
the courses so as to cater to the specific training needs of companies.
In addition to delivering top notched training courses, CPTC’s expertise had
been further tapped by governmental agencies and industry partners to lead
the quality of the workforce through the following areas:
Development of Competency Frameworks and Qualifications
Utilising its experience in developing competency frameworks for the workforce
in its global engineering projects, Petrofac Training Services partnered with the
Singapore Workforce Development Agency to develop Singapore Workforce
Skills Qualifications (WSQ) program for the chemicals industry in Singapore.
WSQ is a robust and integrated continuing education and training system in
Singapore. Designed to build industry competencies, it is founded on best
international practices and validated by industries and employers. WSQ is
designed to facilitate adult learning, make skills upgrading more accessible to
the workforce and provide career progression pathways for them. It also aims
to equip the workforce with the necessary employability, industry and
occupational skills to remain competitive and add value to the organisation.
Industry partners have further engaged this expertise through CPTC to bring
their workforce’s competency-based learning to an entirely new level.
Design and Development of Customised Dynamic Process Training Skids and
Pilot Plants
Leveraging from Petrofac’s experience in providing real life solutions to the
industry, CPTC offers expertise in engineering design of control systems with
the latest instrumentation technology.
Over the years, with this expertise, CPTC has delivered many Dynamic Process
Training Skids which resulted in realistic process models giving real-time
training modules. These training skids are
designed to the customer’s requirement,
based on the competence levels required
by the plant users. Such designs include
Liquid/Gas Separation System,
Temperature, Flow and Level Control
Systems with complex loops having multi
cascade and feed forward controls,
Custody Transfer Flow Metering Systems.
Competence Based Training & Assessment Chemical Process Technology Centre
CPTC’s Facilities
CPTC is a state of the art training centre with a fully operational life size
Kerosene Distillation Unit (KDU), simulation labs, mechanical and
instrumentation labs and e-learning classrooms.
Process Plant – Kerosene Distillation Unit
CPTC has a fully operational life size Kerosene Distillation Unit (KDU) complete
with:
• Distillation Column
• Hot Oil System
• Fired Heater
• Tank Farm
• Cooling Water System
• Nitrogen System
• Air System
The KDU has a complete arrangement of exchangers, rotating equipment,
instrumentation and is monitored and controlled from a fully functional
Centralised Control Room with an advanced Distributed Control System (DCS).
The CPTC Process Plant provides a unique opportunity to deliver competence
based Operations and Maintenance training to personnel starting their career in
the oil, gas and petrochemicals industry or requiring re-skilling or skill
enhancement. Using in-house or client specific competence based training
curriculum and systems, CPTC provides the ideal environment to develop
competent Operations and Maintenance personnel.
This entire plant, in fact, functions as a giant learning area, outside of the
classroom.
Competence Based Training & Assessment Chemical Process Technology Centre
Distributed Control System Laboratory
In collaboration with Honeywell, the Distributed Control Systems laboratory
houses a dynamic process simulator for oil, gas and petrochemicals industries.
The lab provides trainees the competencies in engineering programming,
configuration and implementation for DCS. Trainees will also get training in DCS
maintenance and troubleshooting in a fully equipped lab with state-of-the-art
control hardware and software with modern man-machine interface for
efficient, safe and optimal plant control.
All trainees have plenty opportunities to work on real-time, "life-like"
processes, without the accompanying dangers of a normal plant operation, in
the safety and comfort of the air-conditioned laboratory.
Instrumentation, Automation and Control Laboratory
The Instrumentation, Automation and Control Laboratory houses a full range of
instrumentation for a series of courses on process control and measurement.
These are foundation courses for those working in the process industry. The lab
consists of process plant measuring devices, control elements, process
analyzers and other measurement and control related equipment.
The laboratory provides hands-on
experience on standard Process
Instrumentation and Control Systems,
e.g. sensors, transmitters and
transducers; control of flow, level,
pressure and temperature; PID
controllers and control valves.
Trainees are exposed to control
strategies for pilot plant operations,
e.g. process dynamic studies;
feedback control; ratio control; cascade control; split range control; controller
tuning.
Competence Based Training & Assessment Chemical Process Technology Centre
Rotating Equipment Laboratory
Collaborating with Flowserve, CPTC’s Rotating Equipment Laboratory offers
courses for industry participants on pumps, mechanical seals and system
reliability in a spacious training and well equipped environment.
In the static section, trainees are
expected to get fully hands-on with
the wide range of lab equipment eg.
pumps, valves and mechanical seals.
These include performing
experiments, doing measurement
checks, assembling and disassembling
equipment and performing integrity
checks. The trainees would be
equipped with competencies to cope
with on-site or off-site situations
encountered in their work. The experience of the trainees is further enhanced
with the various assortments of pumps, seals and valves models on display and
these models are exhibited in the form of cutaways, or in full or partially
assembled states.
In the power lab, arrays of six pumping systems are available for trainees to
perform different types of lab exercises. The training laboratory is designed
for hands-on training, a special
feature being the “see through”
pump design which allows
trainees to have a better
understanding of how a pump
works as well as how pump
cavitation occurs. Trainees also
learn about Net Positive Suction
Head (NPSH) principles, which
are important in oil refinery and
chemical process plant
operations. By seeing and
running an actual running pump, the trainees can truly gained knowledge in
pump hydraulics, pump performance curves, causes of mechanical seal and
rotating equipment failure.
Competence Based Training & Assessment Chemical Process Technology Centre
Critical Incident Management Training Suite
As part of the expansion plans and bringing new expertise into Asia, CPTC now
houses a truly new state-of-the-art Critical Incident Management Training
Centre (CIMT). The development of both the facilities and courses had been
carefully planned and based on extensive customer research.
The CIMT has its own emergency
management training software
which can be customised for
clients’ needs. Fully equipped
with audiovisual capabilities and
key event and tally boards. The
whole environment aims to
replicate emergency situations
ranging from a simple false
alarm to full-scale facility
abandonment. Built as a third
generation concept, the CIMT is fully connected with web cams positioned at
various strategic points of observations for record and if required, the training
manager can observe their delegates’ training at any part of the world.
To guide the delegates’ training, observation rooms with its one-way mirror
ensure that the delegates’ performances are assessed and guided by our
qualified instructors and assessors.
Safety Centre
Designed to closely reflect the needs of our clients and the real life
circumstances in which they operate, CPTC Safety Centre allows our trainers to
deliver high quality safety training for the Oil, Gas and Petrochemical
Industries.
Equipped with the latest engineered training apparatus, trainees will have
hands-on experience in real life workplace scenarios balanced with classroom
teaching. Courses are accredited to meet or exceed all relevant international
standards and Code of Practice requirements. Course levels range from basic
understanding of health and safety to tailored specific company inductions such
as Safe Systems of Work, to supervisory and further to senior management level
HSE courses.
Competence Based Training & Assessment Chemical Process Technology Centre
Singapore Petrochemical Industry Career Centre
As a strong partner to WDA as a Continuing Education Training Centre (CET),
CPTC provides its WSQ graduates career advisory services and placement
opportunities with partners in the chemical industries.
With a recognised WSQ qualification, CPTC added value to its WSQ graduates
through its Career Centre. The Career Centre will send the graduates’ resumes
to our participating partners and will help our shortlised graduates to prepare
for their interviews, provide career advice and further development
opportunities.
Auditorium, Function and Seminar Rooms
As value-added service especially to companies on Jurong Island, CPTC also
provides facility rental services at attractive rates. CPTC’s list of facility
resources include:
• 200-seater auditorium
• Function room for receptions or mini-exhibitions and launches
• Seminar rooms for small-group training
The auditorium, function and seminar rooms are fully-equipped with audio-
visual equipment.
Competence Based Training & Assessment Chemical Process Technology Centre
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Competence Based Training & Assessment
CPTC under the management of Petrofac Training Services provides an
extensive range of competence based technical training and assessment,
focusing on skills assessment and development of Operations and Maintenance
personnel for the oil, gas and petrochemical industries.
With the advantage of having a hydrocarbon process plant solely for training
purposes, CPTC conducts competence based operations and maintenance
training including shift rotation, Permit to Work with task risk assessments,
start-up and shut-down exercises, emergency response and fire drill exercises,
offering trainees a unique experience to gain hands-on training on a live plant.
The following outlines the Competence Based Training & Assessment regime
each trainee in CPTC undergoes:
Plant Pre-Operation
Each trainee starts off their training with the main objective of gaining full
competencies to eventual operation of the plant safely and successfully. In
order to achieve that, pre-operation preparation and understanding of the
plant/ system operation will be covered. The trainees will be organised into
teams where the tasks of preparation with task risk reviews will be conducted.
The aim here is to start the plant/ system from cold, in many ways similar to a
commissioning activity, the program will include:
• Understanding the purpose of the process system
• Equipment and process identification and description
• Review of process system
• Review of shut-down and permissives to start through Operating
Manual/ Cause and Effects Narratives
• Review Procedures for:
– Pre-start checks
– Process start
– Process stop
– Emergency shut-down
Competence Based Training & Assessment Chemical Process Technology Centre
– Upset conditions
– Lock out/tag out
– Maintenance Isolation
• Review Plant/ System Readiness
• Availability of air and power
• Electrical motor start checks/ rotation check
• Instrument function checks
• Sign off available for start-up
Control Room Operations
The fully functional Control Room is also a fully integrated training module for
trainees offering them the unique opportunity to experience a real control
room environment complete with Operator Stations, Alarm Annunciators, Event
and Report printers, Radio Interface with Plant, Remote Shutdown, and
Operational CCTV. The integrated training in the Control Room equipped the
trainees with the following essential control room operations competencies:
• Operations and Maintenance Interface
• Permit to Work procedures
• Situation room for Tool box talks
• Plant and or system start-up
• Navigation of process graphics/ alarm summary pages/ tuning pages
• Monitoring process parameters/ alarms
Competence Based Training & Assessment Chemical Process Technology Centre
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• Switch controllers from manual to auto
• Switch controllers from Auto to Cascade
• Adjust set points and observe process response
• Acknowledgement of alarms and alarm/ event reporting
• Data storage and transfer
• Radio protocol from Control room to field and vice versa
• Creation of Fire/ Gas Alarms, response and muster assembly
• Plant or system shut-down
The competencies gained from this training enables the trainee to better
interface with the plant processes/ systems/ maintenance personnel and the
DCS/ information systems.
Plant Operations
Trainees with a strong foundation in place will then be equipped with the
competencies to prepare for the actual start up and operation of the process
plant. The trainee will also be tasked with “on-line” monitoring and control,
and also interface with the maintenance group just like what a process
operator will be carrying out in their role. The competencies will include:
• Plant or System Start-up
• On Line Monitoring and Control
• Field Operator: Monitoring and Logging
• Sample Collection
• Routine Checks
• Maintenance intervention: Tool Box talks, Permit to Work, Task Risk
Assessment
• “Situation” developments, process alarms, Fire/Gas alarms
• Plant Shut-down
The trainees will be grouped into shift teams to perform shift work. Night shifts
can be arranged to increase the authenticity of the training. All training will
be “Competence Mapped” against the relevant Job Profiles, using the building
block determination headings.
Competence Based Training & Assessment Chemical Process Technology Centre
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Petrofac Competent Workforce Scheme
To manage and implement competency based training, through the years of
close partnerships, Petrofac provides clients with a complete managed solution
in respect of competence development for Operations and Maintenance
personnel through the Petrofac Competent Workforce Scheme (PCWS).
The purpose of PCWS is the successful development of personnel by the
application of ‘blended and accelerated learning’ methodologies. It focused on
the person’s job tasks and functions on a specific asset or facility. Unlike most
other forms of training programs, it is based not on time but the person’s
ability to demonstrate competency.
This is achieved by the utilisation of a range of classroom based and CBT
training modules designed to provide the necessary underpinning knowledge for
new entrant and discipline technicians entering into the oil, gas and
petrochemical industries. The curriculum provides solid knowledge and skills
foundation in Production, Instrument, Electrical and Mechanical Operations.
This is combined with a highly structured ‘On the Job’ training program, which
ensures that the main focus of learning is both experiential and relevant to
their job requirements and provides them with ‘real’ skills and experience.
The three entry levels for the PWCS are:
• Apprenticeship entry
• Graduate/cadets entry
• Cross discipline/non-oil and gas discipline entry
PCWS has the flexibility to be aligned to a recognised industry or national
qualification or enterprise-based competencies. If the client does not require a
qualification outcome or have a structured Competency Assurance Program,
Petrofac has a ‘Competency Catalogue’, which contains competencies to suit
the oil and gas ‘up’ and ‘down’ stream facilities, petrochemical and energy
sectors, from which a ‘Competency Portfolio’ can be derived to meet the needs
of a specific job function on an asset or facility.
Competence Based Training & Assessment Chemical Process Technology Centre
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The scheme comprises three main elements:
• Competent Person Profile (CPP) - STRUCTURE
• Pathway to Competence (PTC) - METHODOLOGY
• Competence Management System (CMS)- RECORDING AND TRACKING
CMS
Competence Management
System
Training Scheduling/
Booking
Tracking Assessment Outcomes
Electronic Data
Base
Annual Training
Plan
Status Reports
Competency /Training
Matrix
CPP
Competent Person Profile
Personal Skills Audit
Job/ Position
Description
Competency Catalogue
Course/ Program
Catalogue
PTC
Pathway To
Competence
On-The Job
Training
Computer
Based Training ‘Face
To Face’
Assessment
Vendor/ Supplier Training
Competency
Portfolio
Competency
Profile
Methodology
Competence Based Training & Assessment Chemical Process Technology Centre
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Petrofac Training Courses and Programs
The following courses and programs are delivered by Petrofac Training either at
CPTC or at other Petrofac Training Competency Centres. Some course content
and duration are dependent upon client’s needs and the level of competence
required, and may be customised if necessary.
Process Plant Operations
Course Type Course Code Duration
WSQ Certificate in Process Technology (Chemical) (Full-time)
CT2101 6 weeks
WSQ Certificate in Process Technology (Chemical) (Part-time)
CT2102 10 weeks
WSQ Higher Certificate in Process Technology (Chemical) (Full-time)
CT2201 8 weeks
WSQ Higher Certificate in Process Technology (Chemical) (Part-time)
CT2202 12 weeks
WSQ Certification in Process Technology (Chemical) (Customised)
CT 2203 Customised
Chemical Process Operations Training (Industry) CT5105 6 days
Chemical Process Familiarization Course CT5107 5 days
Process Equipment And Operations Course CT5108 3 to 30 days
Chemical Process Operations Training (NITEC) CT5000 10 weeks
Chemical Process Operations Training (Diploma) CT5003 6 weeks
Aptitude Screening Test for Process Operator CT5104 1 day
Organic Chemistry for Hydrocarbon Process Industry 1 CT5108a 5 days
Organic Chemistry for Hydrocarbon Process Industry 2 CT5109 5 days
Organic Chemistry for Hydrocarbon Process Industry 3 CT5110 5 days
Basic Sciences for Chemical Process Operations CT5111 5 days
BTEC Level 1 Certificate in Process Technology CT6100 5 weeks
Distillation Principles and Equipment CT5112 3 days
Fundamentals of Fired Heaters CT5113 2 days
Heat Exchanger Operations CT5115 3 days
Heat Exchanger Principles and Equipment CT5114 2 days
Operate Compressors and Associated Equipment CT5116 3 days
Competence Based Training & Assessment Chemical Process Technology Centre
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Operate Distributed Control System for Control Room Operators
CT5117 5 days
Process Plant Maintenance
Course Type Course Code Duration
General Maintenance
Basics In Process Plant Maintenance Training CT5201 4 to 12 days
Perform Overhaul & Major Maintenance of Control Valves in a Process Plant
CT5202 3 days
Perform Overhaul & Major Maintenance of Rotating Equipment in a Process Plant
CT5203 3 days
Electrical
A.C. Systems and 3 Phase Systems CT5301 1 day
Fundamentals of AC Generator CT5302 1 day
Fundamentals of DC CT5303 1 day
Perform Electrical Isolation for Equipment Maintenance
CT5305 1 day
Principles of Electrical Safe Working Practices CT5306 1 day
Mechanical
Fundamentals Of Centrifugal Pumps CT1000 2 days
Improving Pump, Mechanical Seal And System Reliability
CT1001 3 days
Fundamentals Of Mechanical Seals CT1100 2 days
Operating Mechanically Sealed Equipment CT1101 1 day
Analyzing Mechanical Seal Failure CT1102 1 day
Process Control & Instrumentation
Process Measurement and Control Appreciation PMCA / CT3000
5 days
Industrial Process Measurement INPM / CT3001
4 days
Industrial Process Control INPC / CT3002
5 days
Competence Based Training & Assessment Chemical Process Technology Centre
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Distributed Control System
Course Type Course Code Duration
Operator
LCN/UCN/GUS for Plant Operators CT4000 5 days
Honeywell Control System Overview CT4002 2 days
Experion PKS Operator CT4050 3 days
Maintenance
UCN/HPM Maintenance CT4005 5 days
TPS System LCN Maintenance CT4006 5 days
HPM Maintenance Refresher Training CT4007 3 days
FSC Controller Maintenance CT4031 3 days
LCN/UCN/HPM(GUS) Maintenance CT4009 5 days
Implementation
TPS System (GUS) Display Builder/ Safeview Implementation
CT4008 5 days
GUS/LCN/UCN Implementation using DEB CT4003 10 days
HPM Points and CL Implementation CT4004 5 days
AM/APP/CL Implementation CT4010 5 days
Uniformance R210 PHD System Administration CT4040 5 days
Administration of Uniformance R210 PHD Background Applications
CT4041 2 days
Uniformance Desktop End User Training CT4042 3 days
FSC Controller Implementation CT4030 5 days
Experion PKS Server Engineering and Configuration CT4051 5 days
Experion PKS Control Execution Environment C300 CT4052 5 days
Experion PKS Graphic Design & Building CT4053 4 days
Refresher
GUS/LCN/UCN Implementation Refresher CT4001 5 days
Competence Based Training & Assessment Chemical Process Technology Centre
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Health, Safety, Security & Environmental
Course Type Course Code Duration
Oil/Petrochemical Safety Orientation Course for Workers (English)
CT0002 1 day
Oil/Petrochemical Safety Orientation Course for Workers (Mandarin)
CT0005 1 day
Hot Work Gas Tester Course CT0006 1 day
Bridging Course for Confined Space Safety Assessor CT0007 3 days
Fundamentals of Quantitative Risk Assessment CT0011 2 days
Process Plant Permit to Work Systems CT0008 3 days
Qualitative Risk Assessment CT0010 2 days
Safety Equipment in a Process Plant CT0009 3 days
NEBOSH Certificate in Health and Safety for the Oil and Gas Industry
CT0013 5 days
Behavioural Safety Programme for Control Room Operator
CT0012 2 days
Critical Incident Management Training
Course Type Course Code Duration
Major Emergency Management Training PTSAP-01-2010 / CT7000
4 days
OIM Controlling Emergencies (Coaching & Assessment) PTSAP-12-2010 / CT7001
2 to 5 days
Control Room Operators Emergency Response Training PTSAP-13-2010 / CT7002
4 days
Control Room Operators (Coaching & Assessment) PTSAP-14-2010 / CT7003
2 days
Emergency Management on Normally Unattended Installations
PTSAP-15-2010 / CT7004
3 days
Certified Track in Emergency & Crisis Management (Supervisory)
CT7005 15 days
Certified Track in Emergency & Crisis Management (Operational)
CT7110 15 days
Competence Based Training & Assessment Chemical Process Technology Centre
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Emergency Response & Crisis Management
Course Type Course Code Duration
Incident Management Training PTSAP-02-2010
/CT7100
2 days
Crisis Management Training PTSAP-03-2010 / CT7101
1 day
Chemical Hazard Awareness Training PTSAP-04-2010 / CT7102
1 day
Media Awareness Training PTSAP-05-2010 / CT7103
2 days
Family Response Training PTSAP-06-2010
/CT7104
1 day
Business Continuity Management PTSAP-07-2010 / CT7105
1 day
Developing Emergency Response Procedures PTSAP-08-2010
/CT7106
1 day
Design & Conduct of Emergency Response Exercises / Drills
PTSAP-09-2010 / CT7107
1 day
Introduction to Incident Command System (ICS) PTSAP-10-2010
/CT7108
1 day
Hazard Awareness for Emergency Responders PTSAP-11-2010 / CT7109
1 day
Please call and email us to get the latest copy of course directory and
quotation.
Competence Based Training & Assessment Chemical Process Technology Centre
Petrofac Training Pte Ltd
Chemical Process Technology Centre
81 Jurong Island Highway
Singapore 627837
Telephone: +65 6880 2000 / +65 6880 2008 / +65 6880 2057
Email: [email protected]
Website: www.cptc.edu.sg / www.petrofactraining.com