To synthesize means to combine, to obtain more complex ones from simple compounds, which is typical for production processes at enterprises chemical industry, where the operator of this profile works. Leads technological process synthesis into the production of vinyl acetate and vinyl ethers. Receives raw materials, loads contact devices and electric furnaces with catalyst and reagents. According to the readings of instrumentation, it regulates temperature, pressure, amount of catalyst in the system, air, and vapor-gas mixture. Collects samples for analysis. Keeps records in the production log. Performs minor repairs of equipment and communications.

Must know

Technological diagram of product production; device and operating principle of the main and auxiliary equipment; purpose and rules for using instrumentation and automation equipment; rules for regulating the technological process, sampling; requirements for raw materials and finished products.

Professionally important qualities

• high degree of stability and distribution of attention;
• good vision.

Medical contraindications

• respiratory diseases;
• allergies.

Paths to obtaining a profession

Related professions

Polymerization operator, mercerization operator, evaporation operator.

6th category

Characteristics of the work. Conducting all stages of the technological synthesis process in equipment with automatic control of process parameters and modes in the production of heavy organic synthesis, aromatic substances, synthetic vitamins, epichlorohydrin, ethylenediamine, dichloroethane or conducting complex chemical synthesis processes associated with the development new technology with the use of explosive and flammable, toxic and potent substances that require exceptional caution, special responsibility, as well as conducting the process of preparation and control of radioisotope raw materials, semi-finished products and finished products in the synthesis of radioactive and stable isotopes.

Studying and recording the features of a new technological process, identifying optimal conditions for obtaining a product with the highest yield and best quality. Determination of the degree of intensity of synthesis processes at each stage, time of start and end of the reaction, product unloading and other parameters using instrumentation, analysis results and organoleptically.

Regulation and adjustment of processes to optimal conditions and switching the process to automatic regulation. Maintenance of multi-section continuous flow columns, autoclaves under pressure over 100 atm, complex installations, synthesis reactors, chromatographic columns, ultrasonic units, extractor-separators and others. Accounting for the consumption of raw materials, semi-finished products and finished products. Management and coordination of the work of workers of all professions at the serviced production site, department or workshop.

Must know: technological process at the site; physical, chemical and technological properties of the raw materials and components used, technical specifications and GOST standards for semi-finished products and finished products; device, design features of main and auxiliary equipment, instrumentation and control devices; diagram of fittings and communications; technological regime and process control rules; methods for calculating dosage components, basics of organic chemistry.

Secondary specialized education required.

Work examples

1. Synthesis of heptal, freons, acrylic acid nitrile by catalytic cyanohydrogenation of acetylene, acetone cyanohydrin, methacrylic and acrylic acids, methacrylic acid esters, polyesters, ethylene cyanohydrin, tributyl phosphate, polynac, organosilicon monomers and liquids by the Grignard reaction, melamine.

2. Synthesis of phenolic, epoxy, melamine- and urea-formaldehyde and other varnish resins.

3. Synthesis of aromatic substances, synthetic vitamins, epichlorohydrin, ethylenediamine, dichloroethane in equipment with automatic process control.

4. Synthesis in the production of technical chlorophos, carrying out the entire cycle of the technological process for the production of cyclopropane (including hydrobromination), isopropylbenzene, isopropylbenzene hydroperoxide, phenol-acetone, ethylene oxide, monoethylene glycol, higher glycols, ethanolamines, proxanols-proxamines, butyl and ethyl cellosolve, diethylene glycol, organic and diacyl peroxides.

5. Synthesis of varnish bases in the production of alkyd varnishes and alkyd drying oils; electrical insulating and unsaturated polyester varnishes by block and azeotropic methods in reactors of various designs; diphenylolpropane varnish resins using the sulfuric acid or hydrochloric acid method; formaldehyde; photographic emulsions for all types of motion picture films, special films, photographic plates, photographic papers, synthesis in the presence of a catalyst in the production of hexamethylene diisocyanate, methanol and isobutyl oil, ammonia, melamine, formal and triisobutylaluminum.

Instructions:

Using the information in this article and the methodology for creating a job description, develop a job description. To evaluate your work, create a topic on the forum. We will always help and appreciate.

AGREED

Deputy HeadVerkhne-DonskoyManagementRostechnadzor

E.N. Sharapov
«___» __________ 2014

I APPROVED

Director of TOGBOU SPO "Kotovsky Industrial College"

A.V. Kochetkov
«___» __________ 2014

PROGRAM

training for a working professionsynthesis operator

Developers: teachers of TOGBOU SPO KIT

Ulukhanova I.V., Tsygankova T.G.

2014

EXPLANATORY NOTE.

This program is designed to train workers in the profession -

synthesis operator.

Training new workers is training workers , without a professionthis, for the purpose of obtaining it.

The program contains an explanatory note, a thematic plan, theoretical and industrial training programs for the preparation of newworkers, list of recommended literature and regulatory documents.

Economic training in the preparation of new workers is carried out according toprograms taking into account work in a market economy,

The volume of professional skills and technical knowledge for each type of training, the volume of working material corresponding qualification categories of this profession provided for by the program, meets the requirements of the Unified Tariff and Qualification Directory (UTKS).

Training of newly hired workers in basic professions is carried out in organizations (institutions) implementing vocational training programs, additional vocational education, entry-level professionalnational education, in accordance with the license for the right to conduct educationative activity. Vocational training programs includeThey provide theoretical and industrial training.

Vocational training programs are consistent with the FederalService for Environmental, Technological and Nuclear Supervision or its territorialrhetorical authorities.

Individual theoretical training of newly hired workers in basic professions is not allowed. Theoretical and industrial training is carried out in a training group.

Industrial training is carried out at educational facilities (workshops, sites, workshops, training grounds, etc.). Conducts industrial trainingunder the guidance of a teacher, industrial training master or highly qualified worker.

At the end of the training, a final exam is conducted to test the theorytechnical knowledge and practical skills of students. Based on exam resultsbased on the protocol of the qualification commission, the student is assignedqualification (profession), rank and a certificate is issued. QualificationThe commission is formed by order of the head of the organization that carried out theeducation. The composition of the qualification commission, by agreement, includes:representatives territorial body Federal Service for Environmental Protectioncivil, technological and nuclear supervision. The composition of the qualification committeemissions do not include the persons who provided the training.

Theoretical training program compiled taking into account the knowledge of educationalwithin the scope of the secondary school program, determines thethe specific content of technical knowledge required by the employee.

The duration of training for new workers is established in accordance with the current List of professions and specialties and ranges from one tofive months.

It is recommended to use a variety of teaching methods in classes,promoting conscious and lasting assimilation of working material anduse various visual aids (process diagrams, equipment drawings, layouts) and technical means training.

When conducting theoretical training, the topic of the program shouldbe studied in full. The program provides training in basicto you professional excellence, which makes it possible for persons who have passed the qualificationqualification exam, start independent work according to the studied spiceality,

Given the continuous technical progress, production programstheoretical and theoretical training must be periodically reviewed andto complement.

Industrial training programs involve studying alloperations and types of work included in the qualification characteristics.Industrial training is carried out under the guidance of a teacher, industrial training master or highly qualified worker with at least 3 years of experience in the specialty, a positive reference and certified as an industrial training instructor, who is responsible for the student’s compliance with all rulessecurity.

In the classroom it is necessary to use effective methods training, linking the material with work in production, use visual aids (process diagrams, equipment drawings, samples of raw materials and finished products), as well as technical training aids.

Industrial training should be combined with the education of students, instilling in them a love for their chosen profession, the ability to creatively decide aboutproduction tasks.

Depending on general education and vocational training students, as well as the level of production in the programs, adjustments are allowedadjustment of the time allocated for studying individual topics, but without changing the generalth number of hours.

PROGRAM

synthesis operator training.

Manufacturing skills.

Synthesis operatorshould be able to:

Accept and hand over shifts;

start and stop serviced equipment from pricesmine control panel (CPU);

with the CPU, start and stop machine mixers, pumps, dosingdevices, set tasks on temperature control devices,level, flow rate, open and close valves, turn onswitch the locks to “automatic mode”;

independently with the CPU, carry out the technological process of obtainingproducts in accordance with technological regulations and operating instructionsworking places, receive liquid raw materials and intermediate products from adjacent buildings and from the warehouses of the enterprise;

with the CPU, launch the collection systems and intake circuitsheating solutions;

check the serviceability of equipment, communications and fittings;

carry out simple repairs of equipment and communications;

prepare equipment for repair and accept it from repair;

carry out a transition on the diagram from one brand of product to another;

stop equipment in case of an accident;

use emergency alarms and protective devicessolutions and fire-fighting equipment;

comply with industrial safety and fire safety regulationsmode;

provide first aid to victims of accidents;

keep records in operational sheets and technological journal;

make calculations of component loads per operation.

Technical knowledge .

Synthesis operatormust know:

- technological schemes for food production, preparation of racescreations, systems for capturing and receiving raw materials from enterprise warehouses;

Rules for working with flammable liquids and flammable liquids;

Design, principle of operation and operating rules of the main andauxiliary equipment;

Communications diagram and fittings, power supply of the workshop;

design and principle of operation of instrumentation,light and sound alarm;

rules of operation and control of the technological process with the centralcontrol panel;

composition and properties of the raw materials and intermediate products used, presentedto them technical requirements according to GOSTs and specifications, methods of storing transportdigging;

rules and regulations for the storage of liquid, bulk and pasty raw materials andintermediate products;

technological modes of food production, preparation of raceswastes and the state of capture systems;

rules for emergency shutdown of equipment;

rules for preparing equipment for repair and starting it up after repair;

internal regulations, industrial safety andfire regime;

methods of providing first aid to victims of accidentsI;

emergency localization plan;

possible problems during the technological process, theirsigns, causes and remedies;

procedure for accepting and turning over shifts;

basic information about product costs, labor organization andprinciples of market economy, fundamentals of quality management;

the procedure for keeping records in operational sheets and in technologicalmagazine.

Thematic plan and industrial training program.

Thematic plan.

Topics

Topic name

Time for trainingreading (hour)

Occupational safety briefingno sanitation, fire safety. Familiarization with the production and operator's workplacesynthesis.

Study of technological schemes, equipment design

production, mastering production management techniques

stvenous process.

Independent performance of work (under supervision)

nim and instructor)

Qualifying exam.

Total:

PROGRAM.

Topic No. 1. Instruction on labor safety, production sledtaria, fire safety. Familiarization with production and working conditionsostomy of the synthesis operator.

Instruction on labor safety, industrial sanitation, firenal safety (to the extent of the relevant instructions for the enterprise and pricexy).

On-the-job training (performed by engineering and technical personnel)shop botnik).

Brief description of the enterprise, the name and purpose of individual workshops, their technical relationship.

Familiarization with the workshop and its a brief description of. Release detailswhich products.

Familiarization with working conditions and rules labor regulations and organization of the synthesis operator’s workplace.

Familiarization with the location of main and auxiliary equipment, production flow diagram, laboratory facilities, mechanicalworkshop, location of household and administrative premises, betweenshop communications, emergency exits, intra-shop alarms.

Potential dangers in the workshop, personal and collective safety measures during work.

Study of the features of industrial sanitation and fire prevention measures in chemical plants.

Familiarization with methods of storing raw materials and auxiliary materialsfishing and finished products.

Rules for the use of respirators, gas masks, safety glasses. Providing first aid in case of accidents. Study of emergency localization plan.

Familiarization with qualification characteristics and the program aboutindustrial training.

Topic No. 2. Study of technological diagrams, equipment design,mastering production process management techniques.

Studying technological schemes for obtaining products and preparingsolutions, raw material reception, recovery systems.

Studying the location of equipment, pipelines, fittings and panelscontrol and measuring instruments.

Studying:

Devices and purposes technological equipment;

location and arrangement of communications, water supply, electricitygas, compressed air, nitrogen;

main malfunctions in the operation of equipment, ways to prevent themtions and eliminations;

emergency situations and rules of conduct in case of accidents and fire.

Mastering techniques:

preparing equipment for operation and its safe maintenance;

starting and stopping equipment in the required sequence;

- preparing equipment for repair, reserve and shutdown in case of accidents.
Acquiring skills to perform simple plumbing work.
Maintenance of control and measuring instruments regulating air conditionersgentlemen.

Participation in the repair of equipment, communications, fittings together withmechanic

Familiarization with automatic control schemes, alarm systemsit and the locking systems used in the technological process,

Carrying out calculations of component loadings for finished product operationsta.

Topic No. 3 . Manufacturing operations training.

Studying the work instructions of synthesis operators.

The procedure for accepting a shift, preparing the workplace for work, checkingcondition of equipment, shut-off and control valves, vehicleticks and blockages.

Mastering the management of processes for obtaining finished products, suitablepreparation of solutions and control of recovery systems from the central control panel (CPU).

Maintenance of recovery systems.

Sample selection. Safety rules for sampling. Sampling schedule.

Registration of technological mode parameters in the technological log and operational sheets.

Prevention and elimination of causes of process disruptions.

Performance necessary measures safety in emergency situations(power outage, water supply interruption, etc.).

Studying the rules, norms and conditions for storing dry, liquid, pasty raw materials, semi-finished products and finished products.

Checking the serviceability of instrumentation and A.

Training in the rules of using light and sound alarms.

Use of personal protective equipment and fire fighting equipmentinventory. Cleaning the workplace. Handing over the shift.

Topic No. 4 . Doing work independently.

Performing all types of work provided for by ETKS for operator operatorssynthesis under the supervision of an industrial training instructor.

Conducting technological processes for obtaining the finished product in accordance with the technological regime and work instructions.

Mastering the skills of independent maintenance of main and auxiliary equipment, workshop communications.

Achieving established labor productivity, obtaining products of the required quality with minimal consumption of raw materials and energy.

Mastering advanced work methods.

Compliance with safety regulations, industrial sanitation, personal hygiene and fire safety regulations.

Independent performance of work in the acquired profession to consolidate and improve practical skills.

Qualifying exam.

THEMATIC PLAN AND THEORETICAL TRAINING PROGRAM

Thematicplan.

Name of topics

Training timetime (hour)

a common part

Introduction

materials science

Reading drawings, diagrams and sketches

1.3

Plumbing Basics

1.4

1.5

The main provisions of the “Technicalmaintenance and repair of chemical equipmentindustrial industry"

Labor protection and industrial safety,industrial sanitation, fire safetydanger

1. 7

Emergency containment plan

1.8

production process

1. 9

Security environment

1.10

Basics of Economics

1.11

Special technology

117 I

2. 1

Technology system production. Conditionssafe conduct of the technological processsa

Design, purpose, principle of operation andrules for the safe operation of the main andauxiliary equipment

Automatic control and managementproduction process

2. 4

Rules for the safe operation of thermalnetworks

Electrical safety rules

Rules for safe operation of pipelinesDov

Repetition of covered material

Total:

PROGRAM.

Topic_No. 1 . Introduction.

The role of the chemical industry in market economy and prospects for its development.

Short story enterprise and its main tasks. Products manufactured by the enterprise, their significance. Enterprise structure, main and auxiliary departments and services, connections between them.

Achievements and traditions of the team. The main features characterizing a worker at a chemical plant. Rational use working timemenu, solving problems in the field of increasing labor productivity and improvingproduct quality.

Rights and responsibilities of the synthesis operator.

Internal regulations at the enterprise, in the workshop, in the team, in the classroomstke.

Qualification requirements for knowledge and skillsparatchik synthesis.

Introduction to the theoretical training program.

Topic No. 1.1 Information on chemistry, physics, electrical engineering,materials science

Information on chemistry.

Structure and composition of matter.

Basic provisions of atomic-molecular teaching.

Simple and complex substances. Concept of chemical elements and themsymbols.

Atomic and molecular masses. Chemical formulas substances. PhysicalChinese phenomena and chemical transformations.

The most important inorganic substances: oxides, bases, acids, salts, their physicochemical properties and composition.

Chemical reactions and equations.

Organic compounds, their structure, physicochemical properties,application.

Aromatic hydrocarbons, their properties and the most important derivatives.

Information on physics.

Aggregate state of substances. Transition from one state of aggregationto another.

Properties of liquid and solid and gaseous bodies

Thermal phenomena. The concept of temperature.

Temperature scale Celsius and Kelvin. Heating and cooling methodsdenition of substances. Thermal conductivity and heat transfer.

The concept of convection, radiation and heat loss into the environmentWednesday. Thermal insulation.

Information on electrical engineering.

Design and principle of operation of electrical equipment and starting apparatusworkshop tours.

Responsibilities of the operator in servicing electrical equipment, itsactions in the event of an electrical equipment malfunction. Protective APparaphernalia, its purpose.

The concept of power supply to a workshop.

Rational use of electricity in the workshop.

Equipment grounding requirements.

The concept of static electricity and protection against it in this industry. Lightning protection of buildings and communications.

Information on materials science.

Selection of construction material for basic chemical equipment. Metals: ferrous and non-ferrous (steel, cast iron, titanium, aluminum, etc.), their properties, scope of application,

Protection of chemical equipment from exposure to aggressive environments. The concept of gumming. Lining with acid-resistant piece materials (brick, diabase tiles, acid-resistant ceramic tiles). Enamelcoverings.

Factors determining anti-corrosion protection devices and pipelines in production.

Corrosion of metals.

Materials for gaskets. Metal materials. Non-metallicmothers of strength.

Topic No. 1.2 Reading drawings and diagrams.

Working drawings and working sketches, their purpose. Image methodsitems. Drawing supplies and tools. Size designationson the drawings. Differences between a drawing and a sketch.

Drawings and assembly drawings, their purpose, the relationship between them. Schemetic depiction of details. Exercises in reading assembly drawings, technicalnological schemes.

Topic No. 1.3 Basics of plumbing.

Metalworking works and their purpose. Types of locksmith work.

Technological process of metalworking of parts.

Selection, preparation and storage of tools, tools and devicesleniya for performing plumbing work.

Mechanization of metalwork.

Padding and padding materials, their use for variousenvironments and temperatures.

Thermal insulation materials.

Lubricants: mineral oils, greases, their use for lubrication of various equipment.

Safety precautions when performing locksmith work.

Topic No. 1.4 Raw materials and auxiliary materials .

Liquid, solid, gaseous raw materials. Rules for storing and handling them. Transportation rules. Safety rules for their use.

Safety rules when working with acids and alkalis.

GOSTs and specifications for raw materials, materials, semi-finished products and finished products.

Energy means: compressed air, nitrogen; their main properties, purpose, transportation. Energy consumption rates and their routessavings.

Topic No. 1.5 Basic provisions of the “System” Maintenance and repair of chemical industry equipment"

The procedure for handing over equipment for repair and receiving it from repair. Types of reinstallation (planned maintenance, capital, related to reconstructionto her).

Contents and execution of documentation (equipment preparation planfor repairs and carrying out repair work, work permits for repairswork, certificates of acceptance of equipment from repair),

Topic No. 1.6 Labor protection and industrial safetysanitation, fire safety.

General information.

Legislation in the field of labor protection.

The Constitution of Russia on the protection and improvement of working conditions.

Characteristics of working conditions in production.

Responsibilities of the administration, workers and employees in the field of securitylabor.

Government bodies supervision over the state of industrial safety and industrial sanitation (Rostechnadzor, Statehot supervision).

Control trade union bodies and trade union representativeslabor protection, industrial safety and industrial safetytari.

The procedure for admitting persons to independent work.

Safety in the workplace.

Possible dangers and accidents at the enterprise, workshop andat the operator's workplace (poisoning, chemical and thermal burns,mechanical injuries, electric shock). The concept of injury. Meaningensuring compliance with technological regulations, instructions and rules of industrial safety, fire safety, industrial sanitation to prevent cases of industrial injuries and professionaldisease.

Harmful effects on the human body of products used in production, maximum permissible concentrations.

Characteristic signs of poisoning harmful substances. Methodsfirst aid. Classification of gas hazardous places, Main reasonsrelease of harmful gases and vapors in the air production premises(violation of technological standards, product spills, violation of sealequipment accuracy, poor work ventilation, etc.).

Rules for working at height.

Work inside the devices, registration of work orders - clearances and rules aboutcarrying out such work.

Personal protective equipment, rules for their use.

Industrial sanitation.

The importance of observing the established working hours and rest for workers.

Sanitary and hygienic condition of the working meta.

The influence of production factors on occupational and general morbidity among workers,

Basic preventive and protective measures to prevent occupational diseases. Medical examination and health carefriendly service, free meals and other benefits for harmful conditionslabor.

Air condition monitoring.

Types of artificial and natural ventilation in the workshop. The concept of air exchange rate.

Types of water supply. Places for installing risers.

Design and types of sewerage.

First aid in case of accidents, contents and racesposition of first aid kits.

Fire safety.

Fire and explosive properties of substances used in the workshop.

Causes of possible fires in the workshop, measures to prevent thembeforehand.

Basic requirements for compliance with fire safety rules. Actions of workers upon detection of fires in the workshop and on the premisesacceptance. Classification of production by categories of explosion and fire hazardssti, categorization of the workshop and its sections according to fire danger.

Methods of reporting a fire to the fire department, fire alarmation.

Primary means extinguishing the fire. Rules for using them, procedurecontent.

Construction and operation of a fire water supply system.

Explosion-proof lighting device.

The procedure for maintaining entrances, driveways, and passages.

Current laws on liability for violation of fire rulesno security.

Topic No. 1.7 Emergency containment plan.

Localization plan for emergencies and accidents, its contents andmeaning.

Topic No. 1.8 Automatic control and management of the production processleadership

The role of automation in providing safe conditions working. Automatic monitoring, regulation and control systems.

Topic No. 1.9 Environmental protection.

Nature conservation in Russia is a national task.

Constitution of Russia on nature protection and rational useland and its subsoil, water resources, flora and fauna, maintaining clean air and water, ensuring the reproduction of natural resources and improving the environment.

Environmental protection. The concept of a sanitary zone. Types and usessources of waste in production.

Effect of waste on the environment. Methods of neutralization andcleaning Wastewater. Ways to reduce production waste and reduceconcentrations of harmful substances in them.

Responsibility of the enterprise for environmental protection. Meromeasures carried out by the enterprise to prevent pollution of water bodies andatmosphere.

Topic No. 1.10 . Fundamentals of Economics.

When studying this topic, you should be guided by a program drawn up by the enterprise itself, taking into account work in a market economy.nomics.

Topic No. 2 .Special technology

2.1 Technological production diagram. Conditions for safe operation technological process .

Chemistry and technology of production processes.

Detailed study of all stages of the process. Chemistry, essence, possibledeviations from the norms of the technological regime, their signs, causes and measureswarnings,

2.2 Devices and operating rules of the main and auxiliary equipment.

Layout of main and auxiliary equipment,communications. Executive diagram indicating valves and automatic componentski. Device, principle of operation, technical specifications and rules exoperation of main and auxiliary equipment: reaction equipmentpumps, containers for acids and alkalis, measuring cups, refrigerators, Florentine vessels, fans, druk filters.

Types of mixers used in devices.

Fittings and instrumentation.

Structural materials used for the manufacture of equipmentdovaniya.

Methods for protecting equipment from corrosion,

Pumps: principle of operation and design.

Basic parameters of pumps. The procedure for starting and stopping pumps, operational problems and their elimination.

Oil seal packings, rules for eliminating leaks in oil seals.

Possible emergency situations in equipment operation (shutdownelectricity, product spills, shutdown of instrumentation and automation air supply, youfailure of liquid supply pumps, breakdown of communications). Prevention and elimination measures.

Rules for the design and safe operation of explosion-prooffans.

Reasons for rapid wear of equipment. Equipment care rulesvaniyam.

2.3. Automatic process control and management production.

Monitoring and management of the production process according to the readings of instrumentation and laboratory analysis data, monitoring frequency. Control and measuring instruments, their location.

Instruments for measuring pressure (pressure gauges), temperature (mercurythermometers, thermocouples, resistance thermometers), flow rate (rotameters, dephlegmators, induction flow meters), level (float level meters, piezometric), instruments for measuring pH, density, concentration, formass measurements (strain gauges).

Operating principle, device, measurement limits and operating rulestation of devices. Secondary devices: principle of operation, rules of use. Recording devices. Rules for using instrument readings for regulationlation of processes.

Control valves, operating principle of automatic regulatorsditch

Scheme of signaling devices and interlocks.

Manual, automatic and remote control. The order of transition from one control to another.

International system units (SI), its advantage and implementation inchemical industry.

System structure. Basic and additional units, allowedsuitable for use along with SI.

Units temporarily approved for use.

Name of quantities and units of designation,

2.4. Rules for the safe operation of heating networks.

Supervision and maintenance of heating networks. Technical documentation to steam and hot water pipelines. Requirements for the operation of heating networks.

2.5 Electrical safety rules.

Static electricity. Measures to prevent and protect against it.Action electric current on the human body. Types of electric shock.

Precautions when working with electrical equipment. First aid for victims of electric current. Lightning protection.

2.6 . Rules for the safe operation of pipelines.

Pipeline categories.

Communications. Materials used for the manufacture of pipeswaters and flange connections.

Design of flange connections, gaskets used to seal them (rubber, fluoroplastic, etc.).

Shut-off valves, their types (gate valves, taps, valves,elephants, membranes, etc.), design and principle of operation, operating rulestions and installations.

Markings on fittings.

Developed by: senior methodologist

TOGBOU SPO "Kotovsky"

industrial technical school" I.V. Ulukhanova

LITERATURE.

Glinka N.D. General chemistry. M. Chemistry. 30th ed., revised, 2003

AkhmetovII. C. General and inorganic chemistry.4th ed., rev. - M.: Higher. school, ed. Center "Academy", 2001 - 743 s.

Kukin P.P. Safety of technological processes and production. Occupational Safety and Health.4th ed., revised. M.: Higher. school, 2007.

Kasatkin A.G. Basic processes and apparatuses of chemical technology. M.Chemistry. 1973Moscow: Tekhnosphere, 2007

Chekali M.A. Technology of organic dyes and intermediatesducts 2nd ed., revised. - L.: Chemistry, 1980. 472 p.

Klimenko V.P., Economics of the chemical industry. L. Chemistry. 2000 g.

Kuleshov V.P. Basic safety precautions at chemical enterprisesindustry. M. Himdia. 1977

Kuleshov V.P. Protection of nature from pollution by industrial emissions.M, Chemistry. 1979 Chemistry, 1979. – 240 p.

Skuratov Yu.I. Introduction to environmental chemistry. M. Higher school. 1994

Rodionov A.I. Environmental protection technology. M. Chemistry, 1989,

Bobkov A. S. Occupational safety and environmental safety in the chemical industry, M. Chemistry. 1998

Devisilov V.A. Labor safety (occupational safety): Textbook for secondary vocational education. – M. FORUM_INFRA-M, 2002.

Gurvich Ya.N. Directory of a young apparatchik - chemist. M. Chemistry. 1991

Klimenko V.P. Organization and planning of chemical production.L. Chemistry. 1989

Nikiforov A.D., Bakiev T.A., Metrology, standardization and certification. Textbook - M. Higher school, 2002

Yashchura A.I. Directory. Equipment maintenance and repair systemchemical industry enterprises. 2012

Babyak Z.V. Printing design of polymer containers in productiongoods household chemicals. M. NIITEKHIM. 1984

B. Berdyshev. Computer techologies in the production of polymer containers. "Container and packaging", 1995

Makarov Yu.I. Apparatus for mixing bulk materials. M. Mashinostructure. 1973

Medvedeva V.S. Occupational safety and fire protection in the chemical industrythinking. M., Chemistry, 1989

Dianov I.G. Technological measurements and controlchemical production borons - M. Chemistry, 1973

Kulakov M.V. Process measurements and instruments for chemical productionVodstvo-.M. Mechanical Engineering, 1983

REGULATIONS.

the federal law dated July 21, 1997 N 116-FZ (as amended on July 2, 2013) “On the industrial safety of hazardous production facilities”

Administrative regulations of the Federal Environmental Service,technological and nuclear supervision for the implementation of statefunctions for registration of hazardous production facilities and maintenance ofState Register of Hazardous Industrial Facilities, approvedby order of ROSTEKHNADZOR dated September 4, 2007 No. 606;

Fundamentals of Legislation Russian Federation on labor protection;

Federal Law of July 17, 1999 N 181-FZ (as amended on May 9, 2005, as amended on December 26, 2005) “On the fundamentals of labor protection in the Russian Federation”

4. Regulations on the investigation and recording of industrial accidents.Decree of the Government of the Russian Federation dated 03/11/1999 No. 279 with amendments and additions dated 05/24/2000;

5. Rules for the design and safe operation of vessels operating underpressure with addition (PB 03-576-03).

6. Guidelines for the operation and repair of vessels and apparatus operating under pressure below 0.07 MPa and vacuum, RUA-93.

7. Rules for the construction of electrical installations (PUE). 7th edition.

Approved by Order of the Ministry of Energy of Russia dated 07/08/2002 No. 204.

8. Safety rules for the operation of electrical installationsfighters. PResolution of the Ministry of Energy of the Russian Federation dated January 13, 2003 No. 6

"On approval of the Rules technical operation electrical installations of consumers"

9. Federal norms and rules " General rules explosion-proof for explosion- and fire-hazardous chemical and petrochemical and oil refining industries". Order of Rostekhnadzor dated March 11, 2013 N 96.

10. Safety rules for industries using inorganicacids and alkalis. (PB 09-596-03).

11. GOST 17.2.1.04-77*. Protection of Nature. Atmosphere. Sources and meteorological factors of pollution, industrial emissions.

12. GOST 12.0.004-90. Interstate standard. System of standardsoccupational safety. Organization of occupational safety training. 07/01/91

13.RD-03-20-2007 Regulations on the organization of training and testing of knowledge of working organizations supervised by the Federal Environmental Service, technicalnological and atomic supervision.

14.Unified tariff and qualification directory.

15. Labor Code of the Russian Federation.

§ 242. Synthesis operator 4th category

Characteristics of the work. Conducting one or two chemical stages of the technological process of synthesis, as well as processes accompanying them, until a semi-finished product or finished product is obtained. Reception and preparation of raw materials used. Preparation of solutions and mixtures. Calculation, dosage and loading of raw materials, solutions and other components into devices strictly according to the recipe while observing the established sequence. Monitoring and regulation of technological parameters of the synthesis process according to the readings of instrumentation and analysis results. Conducting related processes: saturation, neutralization, filtration, crystallization, sedimentation, centrifugation and others. Carrying out analyses. Accounting for the consumption of raw materials used, intermediate products and the yield of the finished product, assessing their quality. Maintenance of various types of reactors, settling tanks, neutralizers, dryers, autoclaves, heaters, separators, evaporators, centrifuges, filters, traps, measuring tanks, extractors, mixers, gas tanks and other equipment, communications. Identifying and eliminating malfunctions in the operation of serviced equipment, checking the tightness of serviced devices and communications. Maintaining records in a technological journal. Cleaning of serviced equipment and mechanisms. Delivery and acceptance of equipment from repair.
Must know: the ongoing technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the control and measuring instruments used; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used, the resulting intermediates and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations.
Work examples.
Conducting the process:
1. Alkylation.
2. Amination of organic compounds and other processes accompanying amination (amination of heterocyclic bases under pressure).
3. Acetylation by the action of acetic acid or acetic anhydride.
4. Bromination of inorganic compounds.
5. Cooking of bakelite varnish, primers (for bookbinding, shoe fabrics, tracing paper), pigments (for artistic paints), decorative facing materials, magnesia (black boiling), chemicals (production of sulfur dyes).
6. Diazotization.
7. Carboxylation of organic compounds.
8. Methoxylation of organic compounds.
9. Nitration of organic compounds.
10. Nitrosation.
11. Synthesis of formal, varnish bases in the production of oil-rosin, bitumen, copal, amber varnishes, amide varnishes and alkyd drying oils using the block method (up to 5 items on one equipment); varnishes on phenolic resins; alkyd resins in the production of polymer building materials and artificial leather; photo emulsions at the stages of washing, second maturation and preparation of photo emulsions for irrigation; hydroxylamine sulfate, caprolactam.
12. Sulfonation of solid and liquid products with sulfuric acid, oleum, sulfuric anhydride within narrow temperature limits.
13. Phosgenation of organic compounds.
14. Cyanidation of organic compounds to produce benzyl cyanide, progesterone, cyanoacetic ester, ammonium thiocyanate and others.

From July 1, 2016, employers are required to apply professional standards, if the requirements for the qualifications that an employee needs to perform a certain labor function, installed Labor Code, federal laws or other regulations (Federal Law of May 2, 2015 No. 122-FZ).
To search for approved professional standards of the Ministry of Labor of the Russian Federation, use

Unified Tariff and Qualification Directory of Works and Professions of Workers (UTKS), 2019
Issue No. 24 ETKS
The release was approved by Order of the Ministry of Health and Social Development of the Russian Federation dated March 28, 2006 N 208

Synthesis operator

§ 240. Synthesis operator of the 2nd category

Characteristics of work. Performing individual operations of the synthesis technological process under the guidance of a synthesis operator more than highly qualified. Preparation and loading of raw materials used. Preparing containers and unloading the product. Cleaning of serviced devices.

Must know: individual operations of the ongoing technological synthesis process; device, operating principle of the equipment being serviced; physical, chemical and technological properties of the raw materials used and finished products, requirements for them.

Work examples.

1. Performing individual operations of the acetylation process.

2. Performing individual operations of the cooking process under the guidance of a more highly qualified synthesis operator.

3. Gelatinization of photographic emulsion, grinding of photographic emulsion in cutting machines.

§ 241. Synthesis operator of the 3rd category

Characteristics of work. Conducting the technological synthesis process under the guidance of a synthesis operator of a higher qualification or performing individual operations of the stages of the synthesis process. Reception of raw materials used, preparation of solutions and mixtures, dosage of raw materials and materials. If necessary, heat and stir the mass. Monitoring and regulation of technological parameters of the synthesis process according to the readings of instrumentation and analysis results. Sample selection. In cases provided for by the technological process, cooling, washing, filtration of the product. Unloading of finished products and transfer to a warehouse or further operation. Carrying out the necessary calculations. Maintenance of equipment and communications. Troubleshooting of serviced equipment. Cleaning of serviced equipment and mechanisms, preparing them for repair.

Must know: the ongoing technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the control and measuring instruments used; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations.

Work examples.

Conducting the process:

1. Alkylation in an acidic environment.

2. Amination of organic compounds and related processes in the production of acetylcholine chloride, riboflavin, calcium pantothenate.

3. Acetylation in the production of phenacetin.

4. Bromination (individual operations).

5. Cooking briquette mass (timber chemical production), liquid glass, oil (for impregnation of asbestos technical products), syrups (production of vitamins), chemicals (production of sulfur dyes, gramophone records), magnesia (white cooking).

6. Diazotization (individual operations).

7. Carboxylation in the production of pass-sodium or individual operations of the process of carboxylation of organic compounds.

8. Methoxylation (separate operations).

9. Nitration of organic compounds under the guidance of a more highly qualified synthesis operator.

10. Nitrosation under the guidance of a more highly qualified synthesis operator.

11. Sulfonation in industries that do not require strict adherence to temperature conditions.

12. Phosgenation of organic compounds (individual operations).

§ 242. Synthesis operator of the 4th category

Characteristics of work. Conducting one or two chemical stages of the technological process of synthesis, as well as processes accompanying them, until a semi-finished product or finished product is obtained. Reception and preparation of raw materials used. Preparation of solutions and mixtures. Calculation, dosage and loading of raw materials, solutions and other components into devices strictly according to the recipe while observing the established sequence. Monitoring and regulation of technological parameters of the synthesis process according to the readings of instrumentation and analysis results. Conducting related processes: saturation, neutralization, filtration, crystallization, sedimentation, centrifugation and others. Carrying out analyses. Accounting for the consumption of raw materials used, intermediate products and the yield of the finished product, assessing their quality. Maintenance of various types of reactors, settling tanks, neutralizers, dryers, autoclaves, heaters, separators, evaporators, centrifuges, filters, traps, measuring tanks, extractors, mixers, gas tanks and other equipment, communications. Identifying and eliminating malfunctions in the operation of serviced equipment, checking the tightness of serviced devices and communications. Maintaining records in a technological journal. Cleaning of serviced equipment and mechanisms. Delivery and acceptance of equipment from repair.

Must know: the ongoing technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the control and measuring instruments used; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used, the resulting intermediates and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations.

Work examples.

Conducting the process:

1. Alkylation.

2. Amination of organic compounds and other processes accompanying amination (amination of heterocyclic bases under pressure).

3. Acetylation by the action of acetic acid or acetic anhydride.

4. Bromination of inorganic compounds.

5. Cooking of bakelite varnish, primers (for bookbinding, shoe fabrics, tracing paper), pigments (for artistic paints), decorative facing materials, magnesia (black boiling), chemicals (production of sulfur dyes).

6. Diazotization.

7. Carboxylation of organic compounds.

8. Methoxylation of organic compounds.

9. Nitration of organic compounds.

10. Nitrosation.

11. Synthesis of formal, varnish bases in the production of oil-rosin, bitumen, copal, amber varnishes, amide varnishes and alkyd drying oils using the block method (up to 5 items on one equipment); varnishes on phenolic resins; alkyd resins in the production of polymer building materials and artificial leather; photo emulsions at the stages of washing, second maturation and preparation of photo emulsions for irrigation; hydroxylamine sulfate, caprolactam.

12. Sulfonation of solid and liquid products with sulfuric acid, oleum, sulfuric anhydride within narrow temperature limits.

13. Phosgenation of organic compounds.

14. Cyanidation of organic compounds to produce benzyl cyanide, progesterone, cyanoacetic ester, ammonium thiocyanate and others.

§ 243. Synthesis operator of the 5th category

Characteristics of work. Conducting three or more chemical stages of the technological process of synthesis, as well as accompanying processes, until a semi-finished product or finished product is obtained. Calculation, dosage, sequential, strictly regulated in time, weight and temperature loading of components into the reactor. Regulating the speed of rotation of the stirrer, creating a vacuum. Accounting for raw material consumption and finished product yield, quality assessment based on analysis results. Prevention of deviations of technological parameters from the specified technological mode and elimination of any deviations that have arisen. Sampling and analysis. Adjustment of the synthesis process based on analysis results. Maintenance of equipment, communications, automation equipment. Troubleshooting of serviced equipment and communications; cleaning of equipment and mechanisms. Maintaining a technology journal.

Must know: technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the used instrumentation and automation equipment; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations.

Work examples.

Conducting the process:

1. Alkylation of complex organic substances.

2. Amination in the production of amidocarboxylic acid.

3. Acetylation in the production of synthetic vitamins A and E, organic substances that require special care and rigidity in the process.

4. Bromination of organic compounds in an acidic environment or an environment of organic solvents.

5. Cooking in the production of ion-exchange and phenol-formaldehyde resins and varnishes, urea-formaldehyde resins, polysulfides, polyvinyl chloride plastic compound, faolite, epoxy varnishes and organic intermediates.

6. Diazotization (production of phenylmethylpyrazolone).

7. Imidation in the production of diphenylguanidine.

8. Carboxylation.

9. Xanthogenation of alkali cellulose, alcoholates.

10. Methoxylation.

11. Nitration in the production of trinitro products.

12. Synthesis of phenolic, epoxy, melamine and urea formaldehyde and other varnish bases; synthesis of acrylic acid nitrile, cyanuric chloride, tetraethyl lead, bromoethyl, organophosphorus pesticides, methacrylic and acrylic acids, acronal, hydrocyanic acid, acrylic emulsion and similar products; synthesis of diphenylolpropane by sulfuric acid or hydrochloric acid method; varnish resins; varnish bases in the production of alkyd varnishes, electrical insulating and unsaturated polyester varnishes and alkyd drying oils; photo emulsions at the stage of first and second maturation and preparation of photo emulsions for irrigation; ferromagnetic powder, cobalt and other components for the production of magnetic tapes; sodium hypochlorite, azodinitrile diisobutyric acid; hydroxylamine sulfate, caprolactam.

13. Sulfonation with chlorosulfonic acid in the production of streptocide.

14. Phenylation.

15. Phosgenation in the production of toluene diisocyanates and toluene diamines, dimethyldiphenylurea, diethyldiphenylurea or the production of metal chloroformate in the production of phenylmethylurethylane.

16. Cyanidation of organic compounds by the action of copper cyanide complex, sodium or potassium cyanide and other cyanide compounds.

§ 244. Synthesis operator of the 6th category

Characteristics of work. Conducting all stages of the technological synthesis process in equipment with automatic control of process parameters and modes, conducting complex chemical synthesis processes associated with the development of new technologies, using explosive, toxic and potent substances, as well as conducting the process of preparation and control of radioisotope raw materials, semi-finished and finished products products in the synthesis of radioactive and stable isotopes. Studying and recording the features of a new technological process, identifying optimal conditions for obtaining a product with the highest yield and the best quality. Determination of the degree of intensity of the synthesis process at each stage, the start and end time of the reaction, product unloading and other parameters according to the readings of instrumentation, analysis results and organoleptically. Regulation and adjustment of ongoing processes to optimal conditions and switching the process to automatic regulation. Accounting for the consumption of raw materials used, semi-finished products obtained and the yield of the finished product. Maintenance of equipment and communications.

Must know: technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the control and measuring instruments used; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used, the resulting semi-finished products and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations; basics of organic chemistry.

Work examples.

1. Conducting all stages of the alkylation process in the production of ethylbenzene, isopropylbenzene, butylphenone, ortho-cresol, NP-3 sulfonol.

2. Conducting the process of acetylation of cotton cellulose to produce cellulose acetate and cellulose triacetate products.

3. Conducting the sulfonation process in the production of synthetic fatty acids.

4. Synthesis in the production of technical chlorophos, cyclopropane, isopropylbenzene, isopropylbenzene hydroperoxide, phenol-acetone, ethylene oxide, monoethylene glycol, higher glycols, ethanolamines, diethylene glycol, organic and diacyl peroxides and similar products; hydroxylamine sulfate, caprolactam.

5. Synthesis of heptal, freons, acrylic acid nitrile, acetacyanhydrin, methacrylic and acrylic acids, methacrylic acid esters, polyesters, tributyl phosphate, organosilicon monomers and liquids by the Grignard reaction, melamine.

6. Synthesis of aromatic substances, synthetic vitamins, epichlorohydrin, ethylenediamine, dichloroethane.

7. Synthesis of varnish bases in the production of alkyd varnishes and alkyd drying oils; electrical insulating and unsaturated polyester varnishes, diphenylolpropane varnish resins, formalin, photographic emulsions, special films, photographic plates, photographic papers, synthesis in the production of methanol and isobutyl oil, ammonia, melamine, formal and triisobutylaluminum.

8. Synthesis of phenolic, epoxy, melamine and urea formaldehyde and other varnish resins.

§ 245. Synthesis operator of the 7th category

Characteristics of work. Conducting all chemical stages of 2 or more fundamentally different technological synthesis processes in equipment with automatic control of parameters and modes with high-intensity mixing of components, the process of synthesis of viscous solutions while simultaneously superimposing them on each other in a liquid state on an inclined plane, the synthesis process in a crystallizing medium when working in explosive environments. Study and development of methodological features of conducting new technological processes, regulation and determination of optimal conditions for carrying out multi-stage processes with the introduction of modifiers at the finishing stages. Accounting for the consumption of raw materials, auxiliary materials, and energy resources. Coordinating the work of synthesis operators of lower qualifications.

Must know: technological process of synthesis; diagram of the serviced area, its fittings and communications; device, operating principle of the equipment being serviced; rules for using the control and measuring instruments used; technological regime of the synthesis process and rules for its regulation; physical, chemical and technological properties of the raw materials used and finished products, state standards and technical conditions for them; sampling rules; methods of analysis and calculations.

Secondary vocational education required.

Work examples.

1. Applying viscous liquid emulsions to a moving substrate.

2. Treatment of magnetic powder with cobalt salts.

3. Synthesis of hydroxylamine sulfate, caprolactam.

4. Synthesis of urea in multistage apparatuses at high temperature and high pressure in a crystallizing environment.

5. Synthesis of iron sulfate in an acidic environment.

6. Synthesis of iron sulfate in an alkaline medium with a modifier.

7. Finishing the surface of magnetic powder particles.