Training the Startup Team

The question to answer for this pre-startup task is Who needs training for this process and to what level of detail One method to analyze training needs is offered by the Instructional Systems Design (ISD) technical training model. It points to the job task analysis method mentioned previously (Appendix D, ISD Model and Job Task Analysis Techniques) to identify procedure titles as a first step for determining which job positions require specific knowledge and skills. 

Tolling presents a special consideration that can make the training step easier. Typically a toller s technical staff, operators and mechanics are knowledgeable in the basic operations and tasks related to the toller s specialty. For example, experienced operators may know operations of the reactors, columns, exchangers, and packaging equipment quite well. The mechanical personnel may be very familiar with the required safe work practices, equipment cleaning procedures and maintenance tasks for standard vessels and piping. 

In this case the training focus can be on the special needs of the process in question. The new or revised operating, maintenance, and emergency response procedures should always be reviewed with the workers expected to perform them. Each employee should have an opportunity to ask questions, familiarize himself or herself with the sequence and assure they understand the steps. 

If a toller has a contract to perform the same toll repeatedly, but on an infrequent basis, training should not be overlooked in preparation for restarting the repetitive toll. It is a good practice to provide refresher-training sessions to assure that the personnel have received current training. One company has picked a six-month period between campaigns as the indicator that the operations team needs refresher training. 

Tollers may have an emergency response plan that requires their personnel to respond in an emergency such as a fire, explosion or release. Other tollers may call upon local responders and evacuate. It is essential that training for responders on the emergency response plan procedures should be up-to-date prior to startup of the new toll. For companies in the U.S. that are required to register 

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Adequately training the startup team, supervisors, and operators. 

Startup expenses. These include a living allowance for the startup team, special tests and test equipment, and computer costs until the process is producing specification product. Estimate as 8 to 10% of the TM cost. Operator training is 0 to 4% of M. The total startup expense is 15 to 40% of M. 

The tolling team has analyzed the hazards, addressed the risks and modifications using a management of change system, revised and written procedures, trained the workers, performed a PSSR, and completed any required test runs. The pre-startup phase is complete at this point. 

A pre-startup safety review is a special safety review that is conducted after a modification to the process or operating conditions has been made and before the startup. In this review a team of reviewers ensures that (1) the system is constructed in accordance with the design specifications, (2) the safety, maintenance, operating, and emergency procedures are in place, (3) the appropriate training is completed, and (4) the recommendations from the PHA are implemented or resolved. 

Startup and operating staff requirements must be determined and schedules prepared for their training and integration to the project team at the right moment. 

Work with the project team s installation target date to schedule physical reviews, document preparation, training, and other activities as needed. Try to meet the intended schedule, but never sacrifice pre-startup safety review quality for a deadline. 

Training of employees not directly involved with initial startup is also an issue of concern. When blended properly with a facility s MOC data package requirements, the PSSR team may consider training complete for introduction of... 

Install and operate. Provide a review team to listen to any concerns or problems during the shake-down phase of implementation. It is sometimes difficult to keep up with all of the signatures and the flow of approvals, the handling of the pre-startup requirements, and the training requirements. Many medium-to large-sized organizations are implementing electronic MOC approval systems. 

Pre-startup safety review team leaders would benefit from additional training on the following topics, some of which are available as public courses or possibly offered through your corporate organizational development group ... 

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