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Training Services

Chemical Process Technology Centre


Singapore
Competence Based Operations & Maintenance
Training & Assessment
for the Oil, Gas and Petrochemical Industries

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

CPTCs Expertise
CPTC demonstrates Singapores and Petrofac Training Services commitment to
building and enhancing a world-class workforce.

CPTCs 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. CPTCs
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, CPTCs 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 workforces competency-based learning to an entirely new level.

Design and Development of Customised Dynamic Process Training Skids and


Pilot Plants
Leveraging from Petrofacs 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 customers 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

CPTCs 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, CPTCs 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. CPTCs 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 audiovisual equipment.

Competence Based Training & Assessment

Chemical Process Technology Centre

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:

Petrofac 2010

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

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Competence Based Training & Assessment

Upset conditions

Lock out/tag out

Maintenance Isolation

Chemical Process Technology Centre

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

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.

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Competence Based Training & Assessment

Chemical Process Technology Centre

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 persons 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 persons
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.

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Chemical Process Technology Centre

Competence Based Training & Assessment

The scheme comprises three main elements:

Competent Person Profile (CPP) - STRUCTURE

Pathway to Competence (PTC) - METHODOLOGY

Competence Management System (CMS)- RECORDING AND TRACKING

Job/
Position
Description
Competency
Catalogue

Training
Scheduling/
Booking
Tracking
Assessment
Outcomes

Course/
Program
Catalogue

Personal
Skills
Audit

Electronic
Data
Base

CPP
Competent
Person
Profile

Competency
Profile

CMS
Competence
Management
System

Status
Reports

PTC
Pathway
To
Competence

Competency
/Training
Matrix

Annual
Training
Plan

Vendor/
Supplier
Training

On-The Job
Training
Computer
Based
Training

Assessment
Face
To
Face

Competency
Portfolio

Methodology

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Competence Based Training & Assessment

Chemical Process Technology Centre

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 clients needs and the level of competence
required, and may be customised if necessary.

Process Plant Operations


Course Type

Petrofac 2010

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

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Competence Based Training & Assessment

Chemical Process Technology Centre

CT5117

5 days

Course Code

Duration

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

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

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 Measurement and Control Appreciation

PMCA /
CT3000

5 days

Industrial Process Measurement

INPM /
CT3001

4 days

Industrial Process Control

INPC /
CT3002

5 days

Operate Distributed Control System for Control Room


Operators

Process Plant Maintenance


Course Type
General Maintenance

Electrical

Mechanical

Process Control & Instrumentation

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Competence Based Training & Assessment

Chemical Process Technology Centre

Distributed Control System


Course Type

Course Code

Duration

LCN/UCN/GUS for Plant Operators

CT4000

5 days

Honeywell Control System Overview

CT4002

2 days

Experion PKS Operator

CT4050

3 days

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

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

CT4001

5 days

Operator

Maintenance

Implementation

Refresher
GUS/LCN/UCN Implementation Refresher

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Competence Based Training & Assessment

Chemical Process Technology Centre

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

Course Code

Duration

Major Emergency Management Training

PTSAP-012010 /
CT7000

4 days

OIM Controlling Emergencies (Coaching & Assessment)

PTSAP-122010 /
CT7001

2 to 5 days

Control Room Operators Emergency Response Training

PTSAP-132010 /
CT7002

4 days

Control Room Operators (Coaching & Assessment)

PTSAP-142010 /
CT7003

2 days

Emergency Management on Normally Unattended


Installations

PTSAP-152010 /
CT7004

3 days

Certified Track in Emergency & Crisis Management


(Supervisory)

CT7005

15 days

Certified Track in Emergency & Crisis Management


(Operational)

CT7110

15 days

Critical Incident Management Training


Course Type

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Competence Based Training & Assessment

Chemical Process Technology Centre

Emergency Response & Crisis Management


Course Type

Course Code

Duration

Incident Management Training

PTSAP-022010
/CT7100

2 days

Crisis Management Training

PTSAP-032010 /
CT7101

1 day

Chemical Hazard Awareness Training

PTSAP-042010 /
CT7102

1 day

Media Awareness Training

PTSAP-052010 /
CT7103

2 days

Family Response Training

PTSAP-062010
/CT7104

1 day

Business Continuity Management

PTSAP-072010 /
CT7105

1 day

Developing Emergency Response Procedures

PTSAP-082010
/CT7106

1 day

Design & Conduct of Emergency Response Exercises /


Drills

PTSAP-092010 /
CT7107

1 day

Introduction to Incident Command System (ICS)

PTSAP-102010
/CT7108

1 day

Hazard Awareness for Emergency Responders

PTSAP-112010 /
CT7109

1 day

Please call and email us to get the latest copy of course directory and
quotation.

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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: cptc.singapore@petrofactraining.com
Website: www.cptc.edu.sg / www.petrofactraining.com