HOW TO DEVELOP A TRAINING PROGRAM 如何建立培训程序 Gene

1、Training is done in two phases. The first phase is classroom training followed by the same training in the field or in the control room at the DCS. The following is required training and the order it should be presented. 培训课程分两个阶段完成。第一阶段是室内课程培训，第二阶段是内容相同现场或控制室DCS系统的培训。接下来将介绍必要的培训内容及其顺序。You must writ

2、e a process description of the flow through an assigned job area. This description will include where the stream comes from, pressure, temperature, flow rate(during normal operation) and stream composition. Tell what vessel it enters and what that vessel does. 你必须对指定的工段写出相关的流程描述。这个描述应该包括物流的来源，压力，温度，

3、流量（正常操作时）以及物流的组成。阐明物流经过的容器及容器作用。工艺简介Explain normal process parameters of the vessel and include all associated equipment. Indicate components removed overhead or from the bottoms and the equipment those streams go to next. Repeat the above process description until the process stream leaves the assi

4、gned operating area and goes into the next job area. 解释容器的正常过程参数并包括整个过程所有的辅助设备。标明从容器顶部和底部移走的组分，物流的下一步所进入的设备。重复以上的过程描述直到过程物流离开设定的操作范围而进入下一个工段。Always tell where the process comes from and where it goes. A good operator should always understand how the upstream and downstream process areas affects his

5、job and vice versa. 要告诉整个过程从何而来，去往何处。一个好的操作工应当理解上游和下游工序是怎样影响他的工作的，同时也应该清楚地知道他的工作对上下游工序起到什么样的作用。It is very useful in this phase of training to develop simplifies flow drawings of the job work area and present them as training aids. 这个阶段的培训，准备一份简化的工艺流程图是很有帮助的，它可以作为一份培训材料。a) This process description wi

6、ll then be condensed into a one line checklist for documentation of training. Every piece of operating equipment must be listed and checked off as explained. 工艺简介中应包含一份用以检查之用的清单。每个操作设备都必须被列在清单之上并且作出解释核对。b) During the presentation, the Trainer should be drawing a simplified flow of the equipment on t

7、he white board. When he finishes, it should resemble the simplified sketch he gave the trainee. 在介绍过程中，培训师应当在白板上画出简单的带设备的工艺流程图。培训时画的简图应类似于书面的流程简图。c) After the classroom material has been presented, take the trainee to the field and begin where the feed to his job area comes from and do the classroom

8、 presentation in the field. 在课程材料介绍完之后，应带培训对象去现场并开始讲解他所负责工段的进料来源，在现场来讲解课堂培训的内容。d) At the end of the training session, you should ask the trainee a few questions(5) about the training he just received or to make a simple sketch on the board as review. 在培训部分结束时，应该向培训对象提问关于培训内容的问题（5个），或者要求在展板上画出简单的流程图作

9、为培训回顾。Using the above Process Description, write a Process Description of the Controls. This is the next phase of training. Again, start at the first piece of equipment and describe range of controllers, normal set points, if air opens/closes the valve, FC/FO valves and the shutdown system that appl

10、ies to the equipment. 应用上述的工艺简述，写一份控制过程描述。此内容作为下一阶段的培训。此外，从第一台设备开始，要描述控制点的控制范围，正常的设定点，阀门是气开还是气关，阀门故障关还是故障开，或是否在停车过程中使用此设备等等。IN THIS SESSION YOU REINFORCE PROCESS FLOW DESCRIPTION BY ADDING CONTROLLERS. This covers normal operating conditions. 这部分培训要通过加入控制点来完善过程流程的描述。包括正常的操作条件。Above Steps a)-d) appli

11、es here also 以上a)-d)同样应用于此。Write a process description for the following: 按照以下内容来准备工艺简述a) Normal Startup 正常开车b) Normal Shutdown 正常停车c) Emergency Shutdown 紧急停车Emergency Shutdown caused by ： 造成紧急停车的原因： 1) Unit shutdown matrix 由于单元停车引起的 2) Electrical failure (total power loss) 电力方面的故障(全厂失电) 3) Cooling

12、water failure 冷却水故障 4) Loss of utilities (if applicable) i.e. ASU Shutdown 公用工程故障(如果可用)例如，空分停车 Steps a)-d) applies here also a)-d)步骤同样应用于此After all the training documents have been assembled, you must develop some type of timeline to show how long each section will have to be trained. 所有的培训文件被准备好之后，

13、必须制定一个详细的时间表安排每一部分内容所需培训的时间。Training periods will vary from job to job depending on the amount of equipment associated with each job and the complexity of the control loops and shutdown system. 根据不同工段的设备情况，操作系统和停车系统的复杂性，不同工段的培训周期是不一样的。Unless you are an experienced trainer, it will take several times

14、 until you will actually decide upon a permanent time that is required to present the training. 除非你是一个经验丰富的培训师，否则你将经历几次这样的过程才能对一个培训作出一个确实有效地时间表。Remember, a trainer can tell an operator more in two hours than most can retain. 记住，培训师在两个小时以内告诉操作工的内容要比两个小时以上的内容还要多。Classroom training should be 1.5 to 2 h

15、ours followed by field training which should be 1 to 1.5 hours followed by 30 to 45 minute question review. 课堂培训时间应控制在1.5至2小时，现场培训时间控制在1到1.5小时，然后还有30到45分钟的问题答疑。Try not to exceed 4 hours daily with the trainee then training in the field on his own or asking the area operator to review with him that d

16、ays training. 每天的培训不要超过4个小时，让培训对象自己到现场或是要求操作人员陪同他们一起在现场学习。At this point you have to decide how you will test and qualify a person. 确定如何测试和让培训对象通过考试。The best way to tell if a person is ready to take the job on his own is a TESTTEST. 检验一个人是否已经具备独立工作能力的最好方法就是测测试试。This takes all personalities out of the

17、 picture 测试可以将个人因素排除在外。Everyone is treated equally and fairly because everyone takes the same test. 因为每个人都要进行相同的测试，所以是公平的。Actually there should be an A A and B B test. 实际上，应该有A、B两套测试题。They should be equally as easy/difficult in questions. 在难易程度上两套测试题应该一致。If the trainee does not qualify on the first

18、test, he should be retrained for a shorter period (must be determined now in writing-usually half the original training period) and retested using the alternate test. 如果培训对象在第一次测试中没有通过，那么还需要经过一段时间的再培训（现在必须用书面的文件确认是原来一半的培训时间），然后再用另一份难度相仿的测试题测试。A test could be fill in the blank or essay type (harder f

19、or trainer to grade. Exact answer must be written on a test used to grade the trainee so everyone is clear as what is an acceptable answer). This is the hardest type of question to answer. 测试题可以采用填空题或是简答题（后者较难评分，此类测试题必须要有标准答案，这样便于评分，同时每位培训对象清楚地知道答题的标准。）这种类型的测试题是最难做的。A True or False test- this is the

20、 easiest type test or multiple answer test (A-D to select from) is in the middle as far as difficulty and very easy for the Trainer to grade. 是非题是最简单的测试题，多项选择题（四选一）的难度是居中的，此类测试题便于培训人评分。A test containing all three types of questions is very desirable. 一份测试卷中如果包含了以上三种题型的话是比较合理的。Some people do not reac

21、t well to written tests as education levels will indicate. 培训对象的受教育程度决定了有些人在书面考试上成绩不佳。In order to get a true understanding of what a trainee actually knows a three part test can be administered. 为了真实地了解培训对象的真实水平，可以采用三方面内容的测试。A）Written：写Depending on amount of equipment and control complexity, 50-75 q

22、uestions will give you a good measurement of the trainees skill level. 根据设备的数量和控制的复杂程度，可以准备50-75个问题来测试受培训人，这样就可以了解其真实的技术水平。B）Drawing：画 Again, depending on the size or amount of equipment, ask the operator to make simplified flow drawings. 同样根据设备的尺寸或数量，要求培训对象来画出简图。Simplified flows should include equi

23、pment and control valves. For the gasifier area it would be one. 简图应包括设备和控制阀门。比如拿气化工段来说就可以用一简图来表示。For the Purification area it could be 3 or 4 drawings. 净化工段就需要用3或4张简图来表示。C）Oral Test：口试Take the trainee to the field and ask him to show you how or where to perform job tasks. 带培训对象到现场，要求其说明如何/在那些工作地点履行

24、他的工作职责。This could be 40-60 (30-40 SES) questions depending on size or complexity of job/area. 根据工作/负责区域的大小或复杂程度，可以准备40-60个问题。（SES：30-40个问题即可。） The same would apply to an inside operators test only he would navigate thru the DCS screens and show you how to change the appropriate controller set point,

25、 change from auto to manual vice versa and how to put a loop into cascade control. 同样的测试方法也适用于内操。他可以通过DCS画面来说明如何改变适当的控制设定参数，如何切入自动或手动以及如何投用控制回路等等。The drawing or oral test will indicate if a person had trouble with written questions but knows the job. 对书面考试有困难但操作能力较强的培训对象来说，画图或是口试是很好的测试方法。 If he does

26、 excellent on his oral test, it is a good indication he knows how to perform his job duties. 如果培训对象在口试中表现出色的话，可以说他知道自己岗位的工作内容。A score of 90% is required on each section and gives a true indication of the trainees skill level. 每个岗位的测试成绩要求在90分以上。当然成绩是培训对象技术水平的真实反映。If he succeeds at the 90% level, his

27、shift supervisor must see that he qualifies on the test questions he missed within two weeks. 如果培训对象的成绩达到90分，那么该值班长就要知道他的成绩是合格，而且在为期两周的培训过程中还有哪些培训内容还未掌握。If this type of test is considered too comprehensive, the drawing section could be eliminated but neither of the other two can or the test becomes

28、meaningless. 这种形式的测试包含的内容很广泛，可以不考虑画图部分的测试，但是如果其他两种测试题也没有的包括的话，测试就没有意义了。The drawing part of the test is actually the easiest of the three. 画图部分的测试在这三种题型中是最简单的。If an operator cannot close his eyes, visualize what is in the field and transfer it to paper, then does he really know his work area? 一名操作人员在

29、闭上眼睛后，如果不能在脑海中勾勒出现场的场景然后画在纸上，就说明他根本不了解他的岗位工作是什么。A trainer must be competent and dedicated. 作为一名培训师，必须是胜任的而且专注于培训工作。Your commitment is to qualify this person as a very good operator, not to disqualify him or put him on the job with only partial knowledge. 你的任务就是要将培训对象培训成为一名合格的操作人员，而不是听之任之，或是让其在不完全了解岗

30、位工作的前提下上岗操作。In preparation of a new training program, the Area Engineer must use resources available to them. 在准备新的培训课程时，工段工程师必须利用一切可用资源来开展培训工作。You must use the Supervisors to help you write the process description and controls. The Supervisors must also rely on the Operators to help write job tasks. 你可以要求值班长来协助完成工艺简述和工艺控制。值班长可以要依靠操作人员编写工作任务。Remember, anything the operator must change in the field