Process Operator

Company:

Interested in joining a winning team? A team whose employees share in the ownership of the business and are empowered to make a difference?

ORGANIZATIONAL CONTEXT AND JOB PURPOSE

INEOS Organization:

INEOS is a global manufacturer of petrochemicals, specialty chemicals and oil products. It comprises 15 businesses each with a major chemical company heritage. Its production network spans 65 manufacturing facilities in 16 countries throughout the world. INEOS products make a significant contribution to saving life, improving health and enhancing standards of living for people around the world. Its businesses produce the raw materials that are essential in the manufacture of a wide variety of goods: from paints to plastics, textiles to technology, and medicines to mobile phones - chemicals manufactured by INEOS enhance almost every aspect of modern life.

Business Context:

The INEOS manufacturing complex consists of three world-class manufacturing plants; ethanolamines (EOA), polyglycol (PEG), and glycol ethers (GE). Collectively, all three plants produce over 500 million pounds per year with sales revenue in excess of $250 million per year.   Two of these plants, the polyglycol and glycol ethers plant, are contract manufactured for The Dow Chemical Company. 

A staff of sixty INEOS employees and forty contractors operates the manufacturing plants continuously.  With the exception of supplying raw materials, utilities and some technical support, all activities are handled by the staff at the Plaquemine plant.  These activities include reaction, distillation/finishing, process control, packaging, loading, quality control/quality assurance, maintenance, safety, environmental, and supply chain activities.

Purpose of the Job:

To operate lab equipment and deliver results from analysis to the board operator based on company discipline principles.  Operate field equipment, using the company discipline principles in three production units.  Monitor equipment as a preventative maintenance measure and maintaining a safe and environmentally sound environment.  Operate the process control boards in a safe and environmentally sound manner.  Direct the team as needed with clear and timely communications.  Maintain a continuous learning ambition to gain knowledge and skills to enable an operator to rotate in each job role based on the outlined time frame in the training matrix.

Environment / Context:

This individual will address all immediate activities associated with producing chemicals in three production plants.  A successful candidate will begin on the job training and progress through four different levels that consist of lab operations, outside operations, batch board operations and continuous board operations.  These activities will be performed in a safe and environmentally sound manner and according to company policies and procedures.  The individual will work in a team environment and rotate through these job functions as their skill levels progress.

RESPONSIBILITIES AND ACCOUNTABILITIES

Accountability 1:

Safety, Health, Environment (SHE)

Most important activities

• This position – and all positions – with the INEOS Oxide organization requires that the incumbent commit to learning, following, and practicing INEOS 20 Principles of Process and Behavioral Safety as applicable to the position.  These Principles are posted throughout each Oxide facility, and each employee must commit to following INEOS’ Life-Saving rules on a daily basis.  These rules are posted within each Oxide facility
• Maintain safety as the highest priority of the plant by adhering to and upholding all safety policies and standards
• Lockout/Tagout equipment as needed for the area in which they are certified.
• Issue permits for work on equipment, hot work and confined space entry in the area that they have been certified
• Observe operating procedures and envelopes
• Deviations must be reported and investigated
• Always place the safe operation or shutdown of the asset ahead of production
• Always take the asset to its safest state when in doubt
• Work within the limit of competency and training

Accountability 2:

All Process Operators

Most important activities

• Properly handle product waste in all areas of responsibility based on established operating discipline
• Follow Good Manufacturing Practices (GMP) as dictated throughout the block.
• Maintain lab and plant process knowledge through continuous training courses offered by the company in order to maintain a high level of quality and process knowledge
• Perform job tasks safely as outlined in the SOP
• Practice good housekeeping in all areas of responsibilities
• Provide support as needed to management and operations team to support needs of the plant
• Comply with environmental and regulatory procedures to ensure that INEOS Oxide is regarded as a good neighbor
• Analyse and offload raw materials as needed
• Prepare equipment for maintenance work in a timely and safe manner
• Participate in Asset Care initiatives.
• Perform minor maintenance activities

Accountability 3:

Initial Grade / Outside Operator

Most important activities

• Properly record analytical results in the LIMS program and deliver results to board operator after reviewing all data for quality and notifying the board operator of any known quality or equipment issues
• Catch and analyze process and tank samples for quality for the purpose of process status and logistical needs in the EOA and GE Plant
• Conduct routine lab rounds, based on the established discipline for lab operators
• Conduct minor troubleshooting on lab equipment and notify proper lab personnel when lab issues or inaccuracy in data is suspected due to equipment malfunction
• Conduct thorough outside rounds as per operating discipline principles reporting any equipment issues including leaks of any type and properly communicating any issues
• Properly align valving for pumping tanks and process flows
• Lockout/Tagout equipment as needed and issue safe work permits in the EOA and GE plants.
• Begin training processes for the PEG Plant after completion of required level reviews on the timeline of the training matrix

Accountability 4:

Mid-Grade / Board Operator

Most important activities

• Rotate in the Outside Operator position to complete tasks in a safe manner
• Catch and analyze process and tank samples for quality for the purpose of process status and logistical needs in the PEG plant
• Enter batch data in the Producer program accurately to ensure the run plan is met
• Complete PEG batches from start to finish in a safe and timely manner
• Record analytical results in the LIMS program and after reviewing all data for quality, communicating results to the board operator of any quality or equipment issues
• Operate and make correct adjustments and set points on the MOD Process Control System (DCS)
• Complete outside rounds and troubleshoot field equipment in the PEG plant.
• Lockout/Tagout equipment as needed and enter safe work permits in the PEG plant
• Coordinate with the contract loading group to safely load all PEG products.
• Begin training processes for the EOA and/or GE Board after completion of required level reviews on the timeline of the training matrix

Accountability 5:

Top Grade / Outside & Board Operator

Most important activities

• Rotate in the Outside and PEG Board Operator position to complete tasks in a safe manner
• Continuously monitor the process conditions of Ethanolamines, Glycol Ethers, and assist the PEG operator in monitoring the PEG control board
• Safely and efficiently operate the DCS for the EOA and GE assets.
• Work with the contract loading group to safely load all of the EOA and GE products.
• Communicate with raw materials feeder plants and service departments, such as Glycol 1 and 2, Environmental Operations, Power and Utilities to ensure each individual has needed information to perform their task in a safe and efficient manner.
• Record product transfers from process to storage, and inform necessary personnel
• Take supportive approach to the “Team” concept and participate in decision making
• Record and communicate during shift, all plant performance activity, daily tasks and issues in the process log
• Perform necessary process control adjustments based on analytical results and/or process optimization; ensuring the company’s operating discipline principles are followed
• Perform duties necessary as a First Responder to Emergency Services in accordance with plant discipline principles

SKILLS/COMPETENCIES

Education/Experience

• High School or Equivalent
• Associate’s Degree in Applied Science in Process Technology preferred

Technical Skills

• Prior Chemical Plant experience a plus
• Basic Chemistry knowledge a plus

Behavioral Skills

• Good communications skills (verbal and written)
• Good math skills
• Mechanical aptitude
• Safety Minded
• Good computer skills
• Able to work rotating shift work, including on weekends and holidays
• Able to wear PPE, including respirator.

ADA PHYSICAL REQUIREMENTS, VISUAL ACUITY REQUIREMENTS, AND ENVIRONMENTAL CONDITIONS

The worker is subject to environmental conditions that occur both inside and outside.

Inside

Medium Work:  Exerting up to 50 pounds of force occasionally and/or up to 20 pounds of force frequently, and or up to 10 pounds of force constantly to move objects.

Outside

The worker is subject to atmospheric and potentially hazardous conditions:  One or more of the following conditions that affect the ears, eyes, respiratory system, or the skin:  fumes, odors, dusts, mists, gases, or poor ventilation.

PERFORMANCE INDICATORS

Following are the Primary Key Performance Indicators for this position:

• ISO Compliance
• SHE Performance – zero incidents
• Process Safety – zero incidents
• TAR executed safely
• Reliability >99%
• First Pass Prime >99%
• Meeting compliance with EPA, GMP, DOT and all OSHA regulations
• Meet all departmental annual training and progression goals

Our culture is one of honesty and integrity with an emphasis on safety, health and environmental performance.On our team, people are acknowledged for embracing new practices that help create real value for customers.