HOW DIGITAL TECHNOLOGY
TURNED A DARK-BLUE COLLAR JOB
INTO A LIGHT-BLUE COLLAR JOB

Ch-ch-ch-ch Changes (Turn and face the strain)
Ch-ch Changes. Just gonna have to be a different man/woman.

(“Changes,” by David Bowie altered by YM, 1971)

Like every industrial manufacturing job on the planet, technological advances have transformed the workload and responsibilities of the Process Operator.

In the early 1990s, many Process Operator jobs would still have fit in the “blue-collar” or manual labor classification. The office work and paper pushing was left to the “white collar” office workers or engineers. Those days are over.

Most processing facilities have either retrofit or entirely upgraded to advanced digital control systems because of the need to remain competitive in the marketplace. Any “grass roots” facility (a brand new plant built from the point of testing the soil to determine foundation requirements) would incorporate the latest and greatest digital technology.

Process Operators are expected to understand the operating principles behind a wide variety of data collecting and generating devices as well as be proficient in analyzing the data.

The Process Operator with analytical skills that also knows the difference between a pipe wrench and channellocks and the correct use of each of those tools is a tremendously valued employee.

Technology and Outside Operator Duties

The Outside Operator will use modern devices to ascertain whether or not an atmosphere is safe to work in. In a modern facility, S/he will collect data concerning temperatures, pressures, levels, and flowrates using bar code technology instead of using a pencil and paper reading sheet mounted on a clipboard. These are just two of the many examples of how technology has changed process operations.

S/he will not rely upon an engineer or engineer tech to analyze the readings; the purpose of investing in technology is to enable the Outside Operator to take ownership of the data, understand what it means to the process, and empower him or her to suggest/perform process corrections when necessary. More brain power is expected from modern operators.

The Outside Operator will record their pass-on log notes digitally into a bulk storage device of some type. Work orders and work permits will also be recorded into a centralized system.

The Outside Operator and Control Board Operators will interface with a digital display of some type to complete annual testing, retrieve procedures and forms, be made aware of company directives, etc.

Technology and the Control Board Operator

The Control Board Operator will be surrounded by a dizzying display of graphics that describe the trends of key process pressures, temperatures, levels, and flowrates.

If the Control Board Operator doesn’t like what s/he sees, a change will be made on the touch screen of the Human-Machine Interface (HMI) that interacts with the Digital Control System (DCS) or other interactive control and monitoring software. There will also be digitized graphics depicting the status of processes that operate with on-off control steps synchronized with Programmable Logic Controllers.

In the pre-digital old days, an alert from a general alarm panel would warn the Control Board Operator something was amiss. The Control Board Operator would direct the Outside Operator to investigate in the vicinity of the problem. The Outside Operator would eventually  report back on the source and status of the problem.

Nowadays, there is sufficient space on the control panels to accommodate several alarm states on every input the Control Board Operator could ever wish for. The soundtrack of an unplanned emergency is the simultaneous ringing of all these alarms.

By virtue of accessing the PTOA via internet, PTOA Readers have already indicated that they are comfortable with digital technology. Gaining competency with the technology in the workplace will be second nature for the new generations of Process Unit Operators.

Take Home Message: Careers in process technology require frequent to continuous interface with computers and digitized data. Strictly “blue-collar” jobs in process industries have been eliminated. At a minimum, basic keyboarding skills to input data are required. More desirable potential employees will demonstrate core competencies interpreting, analyzing, and correctly prioritizing actions in response to the constant barrage of digitized information.

Photo credit:    http://g-man-mrknowitall.blogspot.com

©2014 PTOA Orientation Segment 12

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