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

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

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

© Petrofac 2010 10
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

• 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.

© Petrofac 2010 12
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 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.

© Petrofac 2010 13
Competence Based Training & Assessment Chemical Process Technology Centre

The scheme comprises three main elements:

• Competent Person Profile (CPP) - STRUCTURE

• Pathway to Competence (PTC) - METHODOLOGY

• Competence Management System (CMS)- RECORDING AND TRACKING

Job/ Training
Position Scheduling/
Description Booking
Competency
Catalogue Tracking
Assessment
Outcomes
Course/
Program
Catalogue
Electronic
Data
Base
Personal
Skills
Audit CPP CMS
Competent Competence
Status
Person Management Reports
Competency Profile System
Profile

PTC
Competency
Pathway Annual
To Training
/Training
Plan
Matrix
Competence

On-The Job Vendor/

Training Supplier
Training
Computer
Based Assessment
Training ‘Face
To Competency
Face’ Portfolio

Methodology

© Petrofac 2010 14
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 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) CT2101 6 weeks

(Full-time)

WSQ Certificate in Process Technology (Chemical) CT2102 10 weeks

(Part-time)

WSQ Higher Certificate in Process Technology CT2201 8 weeks

(Chemical) (Full-time)

WSQ Higher Certificate in Process Technology CT2202 12 weeks

(Chemical) (Part-time)

WSQ Certification in Process Technology (Chemical) CT 2203 Customised

(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

© Petrofac 2010 15
Competence Based Training & Assessment Chemical Process Technology Centre

Operate Distributed Control System for Control Room CT5117 5 days

Operators

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 CT5202 3 days

Valves in a Process Plant

Perform Overhaul & Major Maintenance of Rotating CT5203 3 days

Equipment in a Process Plant

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 CT5305 1 day

Maintenance

Principles of Electrical Safe Working Practices CT5306 1 day

Mechanical

Fundamentals Of Centrifugal Pumps CT1000 2 days

Improving Pump, Mechanical Seal And System CT1001 3 days

Reliability

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 / 5 days

CT3000

Industrial Process Measurement INPM / 4 days

CT3001

Industrial Process Control INPC / 5 days

CT3002

© Petrofac 2010 16
Competence Based Training & Assessment Chemical Process Technology Centre

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 CT4008 5 days

Implementation

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 CT4041 2 days

Applications

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

© Petrofac 2010 17
Competence Based Training & Assessment Chemical Process Technology Centre

Health, Safety, Security & Environmental

Course Type Course Code Duration

Oil/Petrochemical Safety Orientation Course for CT0002 1 day

Workers (English)

Oil/Petrochemical Safety Orientation Course for CT0005 1 day

Workers (Mandarin)

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 CT0013 5 days
and Gas Industry

Behavioural Safety Programme for Control Room CT0012 2 days

Operator

Critical Incident Management Training

Course Type Course Code Duration

Major Emergency Management Training PTSAP-01- 4 days

2010 /
CT7000

OIM Controlling Emergencies (Coaching & Assessment) PTSAP-12- 2 to 5 days

2010 /
CT7001

Control Room Operators Emergency Response Training PTSAP-13- 4 days

2010 /
CT7002

Control Room Operators (Coaching & Assessment) PTSAP-14- 2 days

2010 /
CT7003

Emergency Management on Normally Unattended PTSAP-15- 3 days

Installations 2010 /
CT7004

Certified Track in Emergency & Crisis Management CT7005 15 days

(Supervisory)

Certified Track in Emergency & Crisis Management CT7110 15 days

(Operational)

© Petrofac 2010 18
Competence Based Training & Assessment Chemical Process Technology Centre

Emergency Response & Crisis Management

Course Type Course Code Duration

Incident Management Training PTSAP-02- 2 days

2010
/CT7100

Crisis Management Training PTSAP-03- 1 day

2010 /
CT7101

Chemical Hazard Awareness Training PTSAP-04- 1 day

2010 /
CT7102

Media Awareness Training PTSAP-05- 2 days

2010 /
CT7103

Family Response Training PTSAP-06- 1 day

2010
/CT7104

Business Continuity Management PTSAP-07- 1 day

2010 /
CT7105

Developing Emergency Response Procedures PTSAP-08- 1 day

2010
/CT7106

Design & Conduct of Emergency Response Exercises / PTSAP-09- 1 day

Drills 2010 /
CT7107

Introduction to Incident Command System (ICS) PTSAP-10- 1 day

2010
/CT7108

Hazard Awareness for Emergency Responders PTSAP-11- 1 day

2010 /
CT7109

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

© Petrofac 2010 19
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