Operator Training Program

OSHA 1910.119(g) COMPLIANT

Operator Training Program

4 progressive levels. 40+ modules. All 10 major refinery process units. From new-hire orientation to advanced process optimization — every module mapped to OSHA requirements.

Curriculum Overview

Each level builds on the previous. Operators progress at their own pace with AI-adaptive assessments.

1

New Hire / Orientation

Week 1-2 | 8 Modules | ~40 hours
1.1
Refinery Overview & Site Orientation
Process flow from crude to products, site layout, control room structure
SafetyFoundational
1.2
OSHA PSM Overview for Operators
What PSM means, the 14 elements, your role in keeping the plant safe
PSM
1.3
Hazard Communication (GHS/SDS)
Chemical labeling, Safety Data Sheets, GHS pictograms, right-to-know
1910.1200
1.4
Personal Protective Equipment
Selection, use, inspection, and limitations of PPE by hazard type
1910.132
1.5
Permit Systems
Hot work, confined space, line breaking, excavation
Safe Work
1.6
Emergency Response & Muster
Evacuation routes, shelter-in-place, muster points, alarm recognition
1910.38
1.7
Lockout/Tagout for Operators
Affected vs. authorized roles, verification procedures, group LOTO
1910.147
1.8
Environmental Awareness
SPCC, RMP, LDAR, stormwater — operator responsibilities
EPA
2

Unit Operations Fundamentals

Week 3-8 | 8 Modules | ~80 hours
2.1
Hydrocarbon Chemistry Basics
Paraffins, olefins, naphthenes, aromatics
Theory
2.2
Distillation Principles
Vapor-liquid equilibrium, tray hydraulics, reflux ratio, pressure effects
Core
2.3
Heat Transfer Fundamentals
Conduction, convection, radiation — how exchangers and heaters move energy
Core
2.4
Fluid Flow & Pumping
Pressure, head, friction loss, pump curves, cavitation, NPSH
Core
2.5
Compression Principles
Gas laws, compression ratio, intercooling, surge, anti-surge control
Core
2.6
Chemical Reaction Basics
Catalysis, exothermic/endothermic, reaction rate, catalyst deactivation
Core
2.7
Process Control Fundamentals
PID loops, cascade, feed-forward, ratio control, DCS interface
Controls
2.8
Reading P&IDs
ISA symbology, line classes, instrument tags, control valve symbols
Core
3

Unit-Specific Training

Week 9-20 | 10+ Modules per unit | ~200 hours

Crude Distillation (CDU)

Desalter through atmospheric tower — from crude charge to product cuts

Covers: Desalter ops, heater management, tower control, pumparound optimization

Vacuum Distillation (VDU)

Atmospheric residue separation under deep vacuum

Covers: Vacuum system operation, ejector maintenance, packed bed monitoring

Fluid Catalytic Cracker (FCC)

The heart of gasoline production — reactor, regenerator, gas plant

Covers: Cat circulation, slide valve control, regenerator ops, emergency procedures

Hydrocracker

High-pressure hydrogen conversion of gas oil to premium diesel and jet fuel

Covers: HP operations, hydrogen management, emergency depressuring

Catalytic Reformer

Low-octane naphtha to high-octane reformate plus hydrogen

Covers: CCR vs semi-regen, catalyst regeneration, chloride management

Alkylation Unit

Light olefins + isobutane = premium alkylate gasoline blendstock

Covers: HF/H2SO4 safety, acid handling, emergency response for acid release

Delayed Coker

Thermal cracking of vacuum residue into lighter products and petroleum coke

Covers: Drum switching, decoking, heater management, coke handling safety

Hydrotreater / HDS

Sulfur removal from multiple refinery streams using hydrogen

Covers: Reactor operations, H2S management, sour water handling

Sulfur Recovery (Claus)

H2S conversion to elemental sulfur

Covers: Thermal/catalytic stages, tail gas treating, sulfur pit safety

Amine Treating

Gas sweetening with amine solution

Covers: Absorber/regenerator ops, amine quality, foaming prevention
4

Advanced Operations

Month 6-12 | 5 Modules | ~60 hours
4.1
Abnormal Situation Management
Recognizing, diagnosing, and responding to process upsets
Advanced
4.2
Process Troubleshooting
Systematic methodology for identifying root causes
Advanced
4.3
Yield Optimization
Maximizing valuable product yields through operating parameter adjustment
Advanced
4.4
Turnaround Preparation
Shutdown planning, equipment isolation, startup sequencing
Advanced
4.5
Incident Investigation
Participating in investigations, evidence preservation, root cause analysis
AdvancedPSM

OSHA 1910.119(g) Compliance — How We Satisfy Every Requirement

OSHA doesn’t just require training — it requires VERIFICATION that employees understood the training.

  • Initial Training — Complete coverage before assignment
  • Refresher Training — Automated 3-year cycle tracking
  • Means to Verify Understanding — Scored assessments with 80% minimum passing threshold
  • Documentation — Auto-generated completion records with employee identity, date, score

Pricing

Transparent pricing. No per-seat licensing. No surprises.

Single Module

$500

One training module with assessment and documentation

  • AI-generated content specific to your unit
  • OSHA-compliant completion record
  • Instructor guide included
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Complete Operator Program

$12,000

Full 4-level curriculum — 40+ modules, all assessments

  • All Level 1-4 modules
  • All 10 process unit modules
  • Refresher training templates
  • OSHA audit-ready documentation
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Annual Refresher Subscription

$4,000/year

Quarterly updated content with new incident case studies

  • Quarterly content updates
  • New incident lessons learned
  • Refresher tracking dashboard
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