Process Plant Operations

Home  >  Services  >  Career Maps and Pathways  >  Process Plant Operations

Process Plant Operations involves the safe operation and maintenance of plant equipment at optimum levels to ensure raw materials are transformed into quality products. All Personnel in this occupational area must perform their functions in compliance with Health, Safety and Environmental Procedures, Regulations and Statutory requirements.

The Process Plant Operator generally operates all machinery and equipment, trouble shoots and rectifies operational problems; isolates, starts or shut down equipment for preventative/ corrective maintenance; provides samples for analysis; prepares logs, time-tables and reports as well as assist in developing and maintaining operating procedures.

Process Plant Operations is a rewarding career, with highly transferable skills that can be utilized in the energy sector, manufacturing sector and various other sectors. Process Plant Operators can work for local and multi-national companies.

The skilled worker at this level works independently with verbal or written instructions. He/she operates plant equipment safely on a daily basis, conducts maintenance checks of equipment, investigates abnormal conditions, troubleshoots and executes corrective actions.

He or she must also be able to prepare technical reports, maintain an effective work environment by following health and safety requirements when performing tasks.

  1. Understand, maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.

  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.

  3. Establish and maintain productive work relationships and communicate work related information.

  4. Start up, operate and shut down all process operating equipment such as rotating and stationary equipment, tanks, safety equipment and communication equipment in normal and emergency situations.

  5. Monitor and maintain process, equipment and environment. It involves completing operational checks, maintaining consumables for plant and process, as well as maintaining plant, equipment and environment free from contaminants.

  6. Capable of preparing equipment for maintenance work and return equipment to service safely.

  7. Identify and troubleshoot abnormal process and plant conditions.

  8. Prepare and take samples to check quality of process.

  1. Written and Oral Communication

  2. Application of numbers/ computation

  3. Work in teams

  4. Basic troubleshooting skills

  5. Document use may include company manuals, company policy and procedures, Health and Safety laws, standard operating procedures

  6. Critical Thinking

  7. Computer Literacy

  8. Continuous Learning

  9.  Adaptability

  10.  Good Work Ethic

  1. Ordinary Levels (Mathematics, English and Chemistry)

  2. Technician’s Diploma from an accredited institution or

  3. Process Plant Operator Certificate from an accredited institution

  4. 1-3 years’ experience in a process plant environment

  1. Operations Shift Supervisor

  2. Process Plant Supervisor

Technical and Core Skills:

  1. Understand, maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  2. Identify potential hazards and take appropriate action to minimise the risks posed. It also includes identifying and dealing with emergency situations.
  3. Establish and maintain productive work relationships and communicate work related information.
  4. Start up, operate and shut down all process operating equipment such as rotating and stationary equipment, tanks, safety equipment and communication equipment in normal and emergency situations.
  5. Monitor and maintain process, equipment and environment. It involves completing operational checks, maintaining consumables for plant and process, as well as maintaining plant, equipment and environment free from contaminants.
  6. Capable of preparing equipment for maintenance work and return equipment to service safely.
  7. Identify and troubleshoot abnormal process and plant conditions.
  8. Prepare and take samples to check quality of process.

Employability Skills:

  1. Written and Oral Communication
  2. Application of numbers/ computation
  3. Work in teams
  4. Basic troubleshooting skills
  5. Document use may include company manuals, company policy and procedures, Health and Safety laws, standard operating procedures
  6. Critical Thinking
  7. Computer Literacy
  8. Continuous Learning
  9.  Adaptability
  10.  Good Work Ethic

Qualification and Experience:

  1. Ordinary Levels (Mathematics, English and Chemistry)
  2. Technician’s Diploma from an accredited institution or
  3. Process Plant Operator Certificate from an accredited institution
  4. 1-3 years’ experience in a process plant environment

Articulation:

  1. Operations Shift Supervisor
  2. Process Plant Supervisor

At this level he/she performs a broad range of functions that includes supervising the activities of operations and associated personnel. He/she analyses and corrects plant performance issues and recommends changes. He/she is responsible for coaching, mentoring and training of operators to follow guidelines for health, safety and environment as well as operational aspects.

  1. Directs and supervises plant operations to ensure health and safety of personnel, protection of the environment, plant and equipment reliability, plant efficiency, product quality, and optimum production.

  2. Manages plant resources and personnel to achieve strategic priorities.

  3. Knows understands and applies plant operating procedures and company policies.

  4. Evaluates and analyses plant performance and takes required actions or recommends solutions.

  5. Takes responsibility for all company assets and activities within his assigned area of responsibility.

  6. Maintains excellent standards of housekeeping on the plant or facility.

  7. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.

  8. Must be able to identify potential hazards and take appropriate action to minimise the risks posed. This also includes identifying and dealing with emergency situations.

  9. Capability to establish and maintain productive work relationships and communicate work related information.

  10. Inculcates strong values and work ethics among the team

  11. Responsible for the training and development of team members.

  12. Ability to prepare advanced technical reports.

  13. Supervise Start Up/Shut Down and operation of Equipment

  14. Supervise Monitoring and Maintain Process, Equipment and Environment

  15. Perform Quality Assurance and Quality Control

  16. Coordinate Isolation of Energy from Plant and Equipment and Return Plant and Equipment to Service

  17. Facilitate troubleshooting of abnormal Process and Plant Conditions

  18. Interpret sample test results

  19. Co-ordinate Team Activities / Supervise a Team

  20. Monitor team performance against work plans and make the necessary adjustments to the plan

  21. Manage projects – plan, schedule, coordinate resources, project management

  22. Handle emergencies and implement response plan

  23. Participate in shut down meetings, review of shut down work packs, SIMOPS, and work management systems as related to work activities

  24. Performance management

  25. Coordinate maintenance activities

  26. Participates in evaluation and mitigation of plant hazards eg hazard and operability (HAZOP) analysis

  27. Deal with Conflicts

  1. Written and Oral Communication

  2. Working in Teams

  3. Problem Solving

  4. Positive Work Ethic

  5. Planning and organization Skills

  6. Quality Control/Quality Assurance Management

  7. Time management

  8. Supervisory Skills

  9. Leadership Skills

  10. Report writing Skills

  11. Incident Investigation

  12. Emergency Response

  13. Computer Literacy

  1. 5 O’Levels inclusive of Mathematics, English and Chemistry

  2. Process Plant Operation Certificate from an Accredited Training Provider and considerable industry experience – minimum 10 years

  3. Relevant Technicians Diploma from an Accredited Training Provider

  4. Supervisory Management Certificate from an Accredited/recognised training institution

  1. Operations Shift Supervisor

  2. Process Plant Supervisor

Technical and Core Skills:

  1. Directs and supervises plant operations to ensure health and safety of personnel, protection of the environment, plant and equipment reliability, plant efficiency, product quality, and optimum production.
  2. Manages plant resources and personnel to achieve strategic priorities.
  3. Knows understands and applies plant operating procedures and company policies.
  4. Evaluates and analyses plant performance and takes required actions or recommends solutions.
  5. Takes responsibility for all company assets and activities within his assigned area of responsibility.
  6. Maintains excellent standards of housekeeping on the plant or facility.
  7. Maintain and apply health, safety and environmental regulations, legislation and procedures in the workplace.
  8. Must be able to identify potential hazards and take appropriate action to minimise the risks posed. This also includes identifying and dealing with emergency situations.
  9. Capability to establish and maintain productive work relationships and communicate work related information.
  10. Inculcates strong values and work ethics among the team
  11. Responsible for the training and development of team members.
  12. Ability to prepare advanced technical reports.
  13. Supervise Start Up/Shut Down and operation of Equipment
  14. Supervise Monitoring and Maintain Process, Equipment and Environment
  15. Perform Quality Assurance and Quality Control
  16. Coordinate Isolation of Energy from Plant and Equipment and Return Plant and Equipment to Service
  17. Facilitate troubleshooting of abnormal Process and Plant Conditions
  18. Interpret sample test results
  19. Co-ordinate Team Activities / Supervise a Team
  20. Monitor team performance against work plans and make the necessary adjustments to the plan
  21. Manage projects – plan, schedule, coordinate resources, project management
  22. Handle emergencies and implement response plan
  23. Participate in shut down meetings, review of shut down work packs, SIMOPS, and work management systems as related to work activities
  24. Performance management
  25. Coordinate maintenance activities
  26. Participates in evaluation and mitigation of plant hazards eg hazard and operability (HAZOP) analysis
  27. Deal with Conflicts

Employability Skills:

  1. Written and Oral Communication
  2. Working in Teams
  3. Problem Solving
  4. Positive Work Ethic
  5. Planning and organization Skills
  6. Quality Control/Quality Assurance Management
  7. Time management
  8. Supervisory Skills
  9. Leadership Skills
  10. Report writing Skills
  11. Incident Investigation
  12. Emergency Response
  13. Computer Literacy

Qualification and Experience:

  1. 5 O’Levels inclusive of Mathematics, English and Chemistry
  2. Process Plant Operation Certificate from an Accredited Training Provider and considerable industry experience – minimum 10 years
  3. Relevant Technicians Diploma from an Accredited Training Provider
  4. Supervisory Management Certificate from an Accredited/recognised training institution

Articulation:

  1. Operations Shift Supervisor
  2. Process Plant Supervisor

At this level he/she is responsible for the production process, manpower planning and directing of the day-to-day operations, as well as implementing continuous improvement initiatives and productivity across the plant. He/she is responsible for performance evaluations and measures to improve performance.

  1. Ensure implementation; management and compliance with all Safety Management policies

  2. Provides direction and leadership to the departmental team to achieve quality, productivity, reliability, efficiency and commitment to standards.

  3. Ensures compliance to production schedules, budget, inventory and data reporting.

  4. Participate in the development of company policies and procedures

  5. Interpret and executes company policies and procedures

  6. Participate in tender evaluations

  7. Develop and submit departmental budgets and participate in capital investment process.

  8. Participates in recruitment and promotion processes

  9. Develop and implement training and development plans

  10. Conduct performance evaluations and implement measures to reward/improve

    performance as needed

  11. Facilitates improvement through team involvement and effective coaching

  12. Ensures that all required plant monitoring and maintenance activities are carried out.

  13. Responsible for ensuring adequate inventory for operations and maintenance

  14. Prepare relevant reports

  15. Implement company approved emergency response plan

  16. Develop and implement process improvement initiatives

  17. Ensure the effective resource allocation

  18. Participates in evaluation and mitigation of plant hazards eg hazard and operability (HAZOP) analysis

  1. Excellent verbal and written communication skills

  2. Understanding company quality procedures

  3. Manage others to achieve results

  4. Team leadership

  5. Motivational skills

  6. Use of Project Management Software

  7. Skill in programme/project planning and implementation

  8. Problem solving and analysis skills

  9. Decision making skills

  10. Time/cost Management

  11. Advance knowledge of MS

  1. Bachelor’s Degree in Chemical or Process Engineering or Mechanical Engineering with 10 years’ experience in process plant environment

    or

    BA Management and Technician’s Diploma EEET, MET, PPO with 15-20 years’ experience

  2. Training Health and Safety management systems

  1. Process Manager

  2. Production Manager

  3. Operations Manager

Technical and Core Skills:

  1. Ensure implementation; management and compliance with all Safety Management policies
  2. Provides direction and leadership to the departmental team to achieve quality, productivity, reliability, efficiency and commitment to standards.
  3. Ensures compliance to production schedules, budget, inventory and data reporting.
  4. Participate in the development of company policies and procedures
  5. Interpret and executes company policies and procedures
  6. Participate in tender evaluations
  7. Develop and submit departmental budgets and participate in capital investment process.
  8. Participates in recruitment and promotion processes
  9. Develop and implement training and development plans
  10. Conduct performance evaluations and implement measures to reward/improve
    performance as needed
  11. Facilitates improvement through team involvement and effective coaching
  12. Ensures that all required plant monitoring and maintenance activities are carried out.
  13. Responsible for ensuring adequate inventory for operations and maintenance
  14. Prepare relevant reports
  15. Implement company approved emergency response plan
  16. Develop and implement process improvement initiatives
  17. Ensure the effective resource allocation
  18. Participates in evaluation and mitigation of plant hazards e.g. hazard and operability (HAZOP) analysis

Employability Skills:

  1. Excellent verbal and written communication skills
  2. Understanding company quality procedures
  3. Manage others to achieve results
  4. Team leadership
  5. Motivational skills
  6. Use of Project Management Software
  7. Skill in programme/project planning and implementation
  8. Problem solving and analysis skills
  9. Decision making skills
  10. Time/cost Management
  11. Advance knowledge of MS

Qualification and Experience:

  1. Bachelor’s Degree in Chemical or Process Engineering or Mechanical Engineering with 10 years’ experience in process plant environment
    or
    BA Management and Technician’s Diploma EEET, MET, PPO with 15-20 years’ experience
  2. Training Health and Safety management systems

Articulation:

  1. Process Manager
  2. Production Manager
  3. Operations Manager

At this level he/she is responsible for maximising production, protecting assets and reducing operating costs and environmental impact.

  1. Develop and implement operations policies

  2. Determines departmental and plant strategic priorities, and objectives.

  3. Develop, manage and approve operating and capital budget

  4. Responsible for the safe and efficient operation of the Plant

  5. Lead the implementation of the safety policies and procedures

  6. Determine optimum manpower requirement and initiate the recruitment process

  7. Review and approve operational procedures

  8. Facilitate and sustain an effective team environment

  9. Determine training requirements to ensure that all personnel are competent to safely operate the Plant

  10. Provide production data for marketing purposes

  11. Ensure compliance with all regulatory requirements

  12. Ensure compliance with all contractual agreements

  13. Responsible for meeting production, efficiency, reliability and product quality targets. Review and submit daily production reports

  14. Assume responsibility in the event of an emergency at the plant in accordance with company approved emergency response plan

  15. Conduct audits on plant e.g. safe system of work (SSOW)

  16. Analyses and optimizes plant performance

  1. Excellent written and verbal communication

  2. Leadership abilities

  3. Problem solving and analytical skills

  4. Time Management skills.

  5. Project Management skills

  6. Team oriented

  7. People focussed

  8. Customer focussed

  9. Outcome focussed

  10. Flexible

  11. Innovative

  12. Detail oriented

  13. Problem solving and analysis

  14. Strategic orientation

  1. Bachelor’s Degree in Chemical or Process Engineering or Mechanical Engineering with 10 years’ experience in process plant environment (5 of which must be in a management position)

    or

    BA Management and Technician’s Diploma EEET, MET, PPO with 15 years’ experience (5 of which must be in a management position)

  2. Training Health and Safety management systems

  3. Relevant technical training as required

Technical and Core Skills:

  1. Develop and implement operations policies
  2. Determines departmental and plant strategic priorities, and objectives.
  3. Develop, manage and approve operating and capital budget
  4. Responsible for the safe and efficient operation of the Plant
  5. Lead the implementation of the safety policies and procedures
  6. Determine optimum manpower requirement and initiate the recruitment process
  7. Review and approve operational procedures
  8. Facilitate and sustain an effective team environment
  9. Determine training requirements to ensure that all personnel are competent to safely operate the Plant
  10. Provide production data for marketing purposes
  11. Ensure compliance with all regulatory requirements
  12. Ensure compliance with all contractual agreements
  13. Responsible for meeting production, efficiency, reliability and product quality targets. Review and submit daily production reports
  14. Assume responsibility in the event of an emergency at the plant in accordance with company approved emergency response plan
  15. Conduct audits on plant e.g. safe system of work (SSOW)
  16. Analyses and optimizes plant performance

Employability Skills:

  1. Excellent written and verbal communication
  2. Leadership abilities
  3. Problem solving and analytical skills
  4. Time Management skills.
  5. Project Management skills
  6. Team oriented
  7. People focused
  8. Customer focused
  9. Outcome focused
  10. Flexible
  11. Innovative
  12. Detail oriented
  13. Problem solving and analysis
  14. Strategic orientation

Qualification and Experience:

  1. Bachelor’s Degree in Chemical or Process Engineering or Mechanical Engineering with 10 years’ experience in process plant environment (5 of which must be in a management position)

    or

    BA Management and Technician’s Diploma EEET, MET, PPO with 15 years’ experience (5 of which must be in a management position)

  2. Training Health and Safety management systems
  3. Relevant technical training as required