Campus Location:
Stanton
Effective Date: 201751
Course Number and Title:
CPO 100 - Intro to Chem Proc Oper Tech
Prerequisite:
SSC 100
Course Credits and Hours:
3 Credits
3 Lecture hours/week
0 Lab hours/week
Course Description:
This course introduces the student to the process
operations on chemical plants. Topics include: process
technician duties, responsibilities, and expectations; plant
organizations; and plant process and utility systems. In
addition, the course exposes the student to an overview of
the Chemical Process Operator Technology program,
including the physical and mental requirements of a
process technician career. Field trips to nearby chemical
plants are also included.
Required Text(s):
Obtain current text book information at
www.dtcc.edu/allschedules or by visiting the Stanton
bookstore. You will need to know the course number and
section.
Additional Materials:
Method of Instruction:
Face-to-Face
Disclaimers:
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Core Course Performance Objectives:
1.
Analyze the roles, responsibilities, and working environment of the
chemical process operator. (CCC-3; PGC-3)
2.
Apply basic chemistry and physics concepts to chemical processing situations.
(CCC-7; PGC-7)
3.
Communicate at a fundamental level utilizing Chemical Process
Industry terminology. (CCC-1; PGC-3)
4.
Identify and describe the purpose of equipment in process, utility, and auxiliary
systems. (CCC-7; PGC-3, 6)
5.
Describe basic safety, health, and environmental standards relative to the
Chemical Process Industry. (CCC-4; PGC-1)
6.
Demonstrate effective teamwork skills and quality improvement
practices. (CCC-3; PGC-3, 7, 10)
7.
Interpret process flow diagrams and piping & instrumentation
diagrams. (CCC-2; PGC-3)
8.
Document knowledge gained during a field trip to a local chemical
plant. (CCC-1; PGC-3)
Measurable Performance Objectives:
Upon the completion of this course, the student will:
1.
Analyze the roles, responsibilities, and working environment of the chemical
process operator.
1.1 Explain the growth and development of the Chemical Process Industry.
1.2 Report the impact of the industry on the community, the
environment, and the economy.
1.3 Identify the industry responses to current issues and trends such as global
competition, safety and environmental regulations, and technology
advancements.
1.4 Describe the responsibilities of the following regulatory agencies:
EPA, OSHA, DOT, and NRC.
1.5 Describe the roles, responsibilities, and expectations of the Process
Technician.
1.6 Discuss the impact of shift work on individual and family relationships.
1.7 List the factors responsible for future role changes of the Process
Technician.
1.8 Describe the difference between work group and teams.
1.9 Identify the characteristics of a “High Performance” or effective team.
1.10 Describe the stages through which a team evolves.
1.11 Identify factors that contribute to the failure of a team.
1.12 Define workforce diversity and its impact on workplace relations.
2.
Apply basic chemistry and physics concepts to chemical processing situations.
2.1 Define the application of physics principles in the Chemical Process Industry.
a. Define matter and the states in which it exists.
b. Use physical property characteristics to describe various states of
matter.
c. Describe three methods of heat transfer.
d. Perform simple calculations to illustrate how the General Gas Law
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explains the relationship between temperature, pressure and volume
of gases.
e. Perform simple calculations to show how Bernoulli’s Law explains
the flow of liquids and gases.
2.2 Define the application of chemistry principles in the Chemical Process
Industry.
a. Describe the relationship between atoms, protons, neutrons, electrons,
and molecules.
b. Define the difference between inorganic and organic chemistry.
c. Explain the difference between chemical and physical properties.
d . Describe the difference between an acid and a base.
3.
Communicate at a fundamental level utilizing Chemical Process
Industry terminology.
3.1 Describe the function of piping and valves in the Chemical Process
Industry.
a. Identify the different materials used to manufacture piping and valve
components.
b. List the different types of piping fittings used in the chemical industry
and their application.
c. List the different types of valves used in the chemical industry and
their applications.
d. Discuss the hazards associated with improper operation of a valve.
e. Describe the monitoring and maintenance activities associated with
valves.
3.2 Describe the purpose of tanks, drums, and vessels in the Chemical Process
Industry.
a. Explain the relationship of pressure to the vessel shape and wall
thickness.
b. Describe the purpose of dikes, firewalls, and containment walls
around tanks, drums, and vessels.
c. Provide examples of major components of tanks, drums, and
vessels.
d. Describe the monitoring and maintenance activities associated with tank
farm operations.
e. Identify the symbols used to represent the different types of tanks,
drums, and vessels on piping & instrumentation diagrams.
f. Describe the different types of reactors and their purpose.
3.3 Describe the function of pumps, compressors, and turbines in the Chemical
Process Industry.
a. Explain the difference between a pump and compressor in terms of
what function each performs.
b. Identify the primary parts of a typical pump, compressor, and steam
turbine.
c. Describe the operations of a typical pump, compressor, and steam
turbine.
d. Explain the difference between a centrifugal and positive
displacement pump or compressor.
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4.
e. Discuss the hazards associated with the improper operation of
centrifugal and positive displacement pumps and compressors.
f. Describe the monitoring and maintenance activities associate with
pumps, compressors, and steam turbine.
g. Identify the symbols used to represent the different types of pumps,
compressors, and steam turbines on piping & instrumentation diagrams.
3.4 Identify which electrical currents are most commonly used in the Chemical
Process industry.
a. Explain the difference between AC and DC current.
b. Describe the function of a typical electric motor.
c. Identify the primary parts of an electric motor.
d. Describe the monitoring and maintenance activities associated with an
electric motor.
e. Discuss the hazards associated with the improper inspection and
operation of an electric motor.
3.5 Describe the purpose of a shell and tube heat exchanger.
a. Identify the primary parts of a typical shell and tube heat
exchanger.
b. Describe the different applications of a typical shell and tube heat
exchanger.
c. Discuss the hazards associated with improper operation of a heat
exchanger.
d. State the monitoring and maintenance activities associated with a heat
exchanger.
e. Identify the symbols used to represent the heat exchanger on a
piping and instrumentation diagram.
3.6 Describe the function of a cooling tower in the Chemical Process Industry.
a. Describe the relationship between a fin fan exchanger and a
cooling tower.
b. Identify the primary parts and support systems of a typical cooling
tower.
c. Describe the different uses of water from a cooling tower.
d. Describe the monitoring and maintenance activities associated
with a cooling tower.
e. Identify the symbols used to represent a cooling tower on a piping and
instrumentation diagram.
Identify and describe the purpose of equipment in process, utility, and auxiliary systems.
4.1 Describe the purpose of a furnace in the Chemical Process Industry.
a. Describe the types of fuel used in a furnace
b. Identify the primary parts used in a typical furnace.
c. Discuss the hazards associated with the improper operation of a
furnace.
4.2 Describe the fundamental principles of steam boiler operation.
a. Identify the major components of a typical fuel-fired steam boiler.
b. State the differences in fire tube and water tube steam boilers.
c. Discuss the hazards associated with improper operation of a
steam boiler.
4.3 Describe the purpose of a distillation column in the Chemical Process
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Industry.
a. Explain how the properties of mixed chemicals affect distillation
operation.
b. Identify the major components in a typical tray-type distillation
column.
c. State the different types of packing used in distillation columns.
d. Describe the temperature and composition equilibriums established in a
typical distillation column.
e. Describe the monitoring and maintenance activities associated with
distillation column operation.
f. Identify the symbols used for distillation columns and auxiliary
equipment on piping & instrumentation diagrams.
4.4 Describe the types of utilities required by a typical chemical plant.
a. Identify the different types of equipment associated with each of the
utility systems found on a chemical plant.
b. Discuss different types of wastewater treatment systems utilized by
chemical plants.
4.5 Describe the different auxiliary systems found on chemical plants.
a. Discuss the equipment associated with flare systems.
b. Describe the equipment associated with refrigeration systems.
c. Discuss the equipment associated with lubrication and hot oil
systems.
5.
Describe basic safety, health, and environmental standards relative to the
Chemical Process Industry.
5.1 Discuss the safety, health, and environmental hazards found in the
Chemical Process Industry.
5.2 Describe the intent and application of the primary regulations impacting
the Chemical Process Industry.
5.3 Demonstrate the personal attitudes and behaviors that can help to prevent
workplace accidents and incidents.
5.4 Identify the consequences of non-compliance with regulations.
5.5 Demonstrate the correct use of personal protective equipment.
5.6 Describe the application of the International Organization of Standards’
ISO-14000 as it relates to the Chemical Process Industry.
6.
Demonstrate effective teamwork skills and quality improvement practices.
6.1 Describe the importance of quality issues to the Chemical Process Industry.
6.2 Explain the role that W.E. Deming, Joseph Juran, and Philip Crosby
played in quality implementation.
6.3 List the four components of Total Quality Management.
6.4 Describe the use of Statistical Process Control (SPC) by the Chemical
Process Industry.
6.5 Describe the roles and responsibilities of the Process Technician in
supporting quality improvement within the workplace.
7.
Interpret process flow diagrams and piping & instrumentation diagrams.
7.1 Identify four key variables that are used to control chemical processes.
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7.2
7.3
7.4
7.5
8.
Draw a generic process control loop.
Describe the major types of process control instrumentation.
Discuss the purpose of a distributive control system.
Identify symbols used to represent process control instrumentation on
piping and instrumentation diagrams.
Document knowledge gain during a field trip to a nearby chemical plant.
8.1 Describe the major products manufactured at the plant and their modes of
shipment.
8.2 Sketch a process flow diagram of the plant operations.
8.3 Describe the key operating parameters for each process step.
8.4 Discuss the five utilities used by the plant.
8.5 Explain the quality control program on the plant.
8.6 List the chemical and physical hazards on the plant.
8.7 Describe the environmental control program on the plant.
Evaluation Criteria/Policies:
Students will demonstrate proficiency on all Core Course Performance Objectives at
least to the 75 percent level to successfully complete the course. The grade will be
determined using the College Grading System:
92 – 100
83 – 91
75 – 82
0 – 74
=
=
=
=
A
B
C
F
Students should refer to the Student Handbook for information on Academic Standing
Policy, Academic Honesty Policy, Student Rights and Responsibilities, and other policies
relevant to their academic progress.
Core Curriculum Competencies: (The competencies every graduate will develop.)
1. Communicate clearly and effectively both orally and in writing.
2. Demonstrate effective problem solving and reasoning skills.
3. Work effectively in groups of people from diverse backgrounds.
4. Demonstrate ethical and professional understanding and conduct.
5. Apply appropriate information literacy skills to locate, evaluate and use
information effectively.
6. Use computer technology appropriate to the field.
7. Use scientific and mathematical reasoning appropriate to the technology.
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Program Graduate Competencies: (The competencies every graduate will develop
specific to his/her major.)
1. Maintain safety, health, and environmental standards in a chemical plant.
2. Handle, store, and transport chemical materials according to all applicable federal, state,
and local regulations.
3. A p p l y chemical process and quality systems safely and efficiently.
4. Operate, monitor, control, and troubleshoot batch and continuous chemical
processes.
5. Analyze samples of raw materials, intermediates, and finished products in a
chemical plant.
6. Perform routine, predictive, and preventive maintenance and service to process
equipment and instrumentation.
7. Apply mathematical and statistical concepts and principles to analyze and
solve chemical process problems.
8. Use computers and computerized equipment for communications and chemical
process control.
9. Communicate effectively orally and in writing.
10. Function collaboratively in teams and independently.
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