Approval

Project manager

Gheorghe
0 November 2018 Initially Bucătaru
Gheorghe Pasăre Simion Manea
NO. DOCUMENT
REV. DATE DESIGNED CHECKED APPROVED
DESCRIPTION
Revision Sheet
CUSTOMER:
MINISTRY OF ELECTRICITY (MOE)
REPUBLIC OF IRAQ
PROJECT :
IFB no. M21-21-2016
Rehabilitation of Unit 3
Facilities and Common System, Al Mussaib Thermal Power Plant Rehabilitation

CONTRACTOR:

BLACK SEA POWER GENERATING FZCO

DESIGNED BY DATE
TITLE:
Gheorghe Bucătaru November 2018
OPERATIONAL PROCEDURE
CHECKED BY DATE Planning and conducting the training procedure
Gheorghe Pasăre November 2018 for Customer’s speciality operating staff
APPROVED BY DATE
WASTE WATER TREATMENT PLANT

Simion Manea November 2018

Contract No. DOCUMENT NUMBER REV.NO.

IFB no. M-21-2016 350-BSP- 0157 0

CONTENT:

No DESCRIPTION PAGE
1. PURPOSE 3

TRAINING METHOD and 4

2.
JOB STRUCTURE OF TRAINEES

TRAINING SCHEDULE and TRAINING 7

3.
MODULES OVERVIEW

RECORDS for APPLICATION OF THE

4. 17
TRAINING PROCEDURE

Page 2 of 20
1. PURPOSE
A central challenge and requirement for ensuring the safety and reliability
of Waste Water Treatment Plant (WWTP) is to attain and maintain the
qualification and competence of plant (WWPT) personnel, which includes
operations, maintenance, management and technical support personnel.

The objectives of safety and reliability cannot be achieved solely by the

quality of equipment and hardware, but depend critically also on sufficient
numbers of personnel having the necessary qualification and competence to
carry out their tasks and responsibilities.

This Operational Procedure is designed to ensure a good organization and

planning of the training and evaluation activities of the personnel assigned to
operate the equipment and facilities in the WWTP in order to facilitate the smooth
and efficient development of the training

The main purpose of planning the training activities is:

• to define the conditions for the safe conduct of the training and the
subsequent operation of the WWTP ‘s facilities,
• As well as to determine the concrete conditions regarding who is
participating in the training,
• How the training program is being carried out,
• What are the facilities necessary to run the training program and
who provides them.

For the technical aspects of the content of the training program:

❖ a Training Course Support (Training Manual) will be available, to

which all learners will have access.

Also, in this operational procedure, the proportion of the theoretical

training sessions and of the practical training sessions is determined.

This operational procedure also establishes how the learners are to be

assessed during and at the end of the training program, as well as how should
be recognized the participation of the trainees in the training program

Page 3 of 20
 2. TRAINING METHOD and JOB STRUCTURE OF
TRAINEES
2.1 TRAINING METHOD

TRAINING can be formal (in official schools) informal (at work place for
example) and non formal (any individual way the trainee choose). This is a
combination of informal and Nonformal training.
Experience has shown that, to attain professional competence, The
Training Program (Training Procedure application) should comprise training to
achieve both the necessary technical and human factors competencies.
Thus, BSP Commisioning Team’s Training Procedure (BSPCTTP)
emphasizes a broader concept of competence which includes not only technical
knowledge and skills but also knowledge, skills and attitudes related to human
factors. In addition to the training of operating personnel, the BSPCTTP deals
with the role and responsibilities of :
o management (coordinators and WWTP heads);
o shifts leaders and maintenance personnel;
o auxiliary / support pesonell involved in WWTP operation

Mainly the BSP Commisioning Team’s Training Procedure is based on the

so-called method:"Training the trainers" (TtheT) for deliver the training program.
This method is more efficient in the concrete conditions from the WWTP site
because it takes into account the possibilities to overcoming of inherent difficulties
related to the in detail understanding of the exposures of the instructor (who is a
Romanian mother tongue who speaks in English) addresses to Iraqi mother tongue
learners who also speak English. In these circumstances, it is preferable to train a
smaller number of trainees who, in turn will become instructors for other learners and
so on, thus ensuring the knowledge and skills, gained through training, spread on at all
levels of the operating staff. Train-the-Trainer is a model used to describe, much as
the name would imply, training potential instructors or less experienced instructors, on
the best ways to deliver training materials to others.
The idea of train-the-trainer is essential to a strong overall training program, and
the aim is not just to improve effectiveness, but also efficiency and productivity.
The goal of many of our Training Program is to have a strong talent pool of trained
trainers from Beneficiary’s staff (able to train further on others), rather than to have only
a few dirrect trained operators who should be obliged to manage in future everything
related of WWTP operating .
Thus, the main tenets behind Train the Trainer are twofold:
➢ First, you can spread knowledge more efficiently among WWTP
operating staff.
➢ Second, you can capitalize on the teaching tactics that help people
retain information quickly.

Page 4 of 20
 2.2 JOB STRUCTURE OF TRAINEES

In order to start and complete the Training Program for WWTP operating staff Beneficiary
should, however, to choose and nominate its champions according to more than just their job
position.
In choosing the Beneficiary’s staff to participate to the training program it is advisable
Beneficiary’s responsible leaders probably thinking of certain people who carry some authority
among their operating staff and shall be later on responsible for the WWTP operation in years to
come.
All trainees nominated by the Beneficiary to attend / participate in the Training Program
conducted according to BSP Commisioning Team’s Training Procedure should participate / attend
/ witness the Commissioning activities.
Trainees nomination (done by Beneficiary) should cover the following job
specialities:

Shift
Other WWTP supervisors
personnel

Control room Field Maintenance

operators operators personnel chief in
charge

Electricians Instrumentation
(MCC + field
electric motors, specialists
transformers, (control panels + field
Invertors, etc) instrumentation)

Mechanical works
PLC – HMI intervention
specialists specialists

 Beneficiary is free to nominate as many trainees as it considers as necessary for covering

its needs for Training
 Based on Beneficiary nomination of trainees number and Job specialities, the BSP
Commisioning Team’s Training Procedure will be tailored (as timtimming and Training
Modules sequencing ) to meet the actual demands.

Page 5 of 20
  The Training Program has a modular structure; Some Training Modules are compulsory for
all trainees / learners, regardless of their specialization, others are specifically addressed to
certain specializations but even these may also be of interest to other specialties; That is
why trainees are encouraged to participate in all training Modules even if some modules
can be considered outside of their field of interest / specialization.
 The training course / training program addresses the operating personnel who will work in
the WWTP and therefore it does not address top management (Plant Manager, Process
Engineer for WWTP etc.). However, any person from the Leadership, if they wish, can
optionally participate in the Training Program and they are welcome (especially as the
training method used in this Training Program is one such as ”Training the Trainers”)

2.3 Main challenges and constraints of Training Method

”TtheT”
❖ Finding out if you get the right individuals who want / are genuinely interested in
participating in the Training Program
▪ and if they wish to continue to train other colleagues further disseminating the knowledge
and skills acquired through the Training Program
▪ make sure all your designated trainers are willing to see the task through to the end.
❖ Be prepared for mistakes
▪ Train the Trainer is a learning process. Even if all participants (trainees) have years of
experience, they may not have experience in WWTP of this Kind. As with any learning
process, if you don't allow your trainers to make some mistakes, they may be hesitant to try
something new again.
▪ Allow enough time for preparation and practice.
▪ It's incredibly rare for something to go smoothly the first time you try it, even if you've spent
a lot of time choosing the right training method
❖ Be prepared for constructive criticism
▪ Whether you're giving it or taking it, constructive criticism will play a direct role for you
throughout the Training process.
▪ Your trainees will be learning from someone who specializes in presentation.
▪ The end goal of Train the Trainer is to maximize efficiency, not necessarily to introduce
creative learning methods.
❖ Track results
▪ your trainees are most likely eager to know how well they taught and what they could do
better the next time around.
▪ show them who is seeking the next steps, or who is following up with "homework"
assignments.
▪ You can also use tactics such as gamification to encourage friendly competition
and reward progress.

Page 6 of 20
 3. TRAINING SCHEDULE and TRAINING MODULES
OVERVIEW
3.1 SCHEDULING THE TRAINING
Mainly the Training of the Beneficiary’s operating staff (who will
eventually take over the Waste Water Treatment Plant(WWTP) for continuous
long lasting operation) is one of the principal activitiy within the complex
Commissioning Process. As long as the Beneficiary’s operating staff it is
advisable to be present and witness on site the Contractor's Commissioning
Team activities during the entire period of testing, inspection, verification and
adjustment, trial works etc. done within the commissioning process / work, The
Training Process shall normally be a continuos one during the whole
Commissioning Process.

If the Beneficiary’s operating staff (designated by the Beneficiary) is

present on the site during Commissioning activities, they take advantage
of continuous training sessions whether these training sessions are held as
formal structured sessions (with theoretical lessons and practical lessons)
scheduled at the beginning of the Commissioning Process, or that they take
place informally (in a way it can be said: naturally, without a specific program)
during the Commissioning process as the Beneficiary's operators are on site
alongwith the BSP Commissioning Team.
Scheduling the Training is focussed on the formal sessions held at the
beginning of Commissioning Process.

Mandatory prerequisites for commencement of the Operators Training

Program for the staff assigned by the Beneficiary to take over the facility for
routine operation after completion of the Commissioning activities:
- designation of the operating personnel who have to attend the informal
training sessions (theoretical lessons + practical lessons) both as number of
persons and specialties (electricians, mechanics, operators, etc.)
- allocation by the Beneficiary of a training area for theoretical lessons with
minimum training facilities(projector, flipchart, tables, chairs, writing tools,
blocknotes etc) appropriate to the number of nominated trainees
- Defining daily time periods in which learners / trainees are relieved of other
job duties for proper attending the formal training sessions
Based on these preliminary informations which will be made available to
the BSP Commissioning Team by Beneficiary, a realistic detalied training
program (by daily hours ) tailored to the number of trainees and their specialties
should be developed.

However the detailed tailored schedule should be compatible with the

training program overall schedule envelope as follows:
Page 7 of 20
 3.1.1 INTEGRATING THE TRAINING SCHEDULE WITHIN
THE OVERALL COMMISSIONING SCHEDULE

First of all it is to be underlined that Commissioning is a complex Process

which is generally composed from about 9 (nine) main sequences:

INFORMAL TRAINING
OPERATORS

NONFORMAL CONTINUOUS TRAINING

FUNCTIONAL TEST OPERATORS

RELIABILITY TEST

HANDING OVER FOR

ROUTINE OPERATION

The sequences are quite in a logical normal order (succession) and only a
few, at the and of the process can be performed in reverse order if required.
Page 8 of 20
 However, timing of sequences is not always done one after the other, there
may be overlapping, gaps, stagnation etc. as the real situations from the site
request.

Thus, the programming of Operator Training should not be rigid (with

particular reference to formal training, since the informal one is clearly dependent
on the actual evolution of the commissioning process on site) but must be flexible,
adapted to the requirements of the actual process and the real training needs of
learners / trainees

3.1.2 Commissioning approaches

Experience proves that there are two main approaches for a

Commissioning Process implementation on site:

a) With "Systems Approach"

b) Without System Approach

Commissioning means in the first instance checking and testing.

The checking and testing phases of a new Waste Water Treatment Plant is
by necessity a relatively detailed and sophisticated process.

Not all parts of the WWT plant (e.g. Abnormal Waste Water Treatment
Section, Normal Waste Water Treatmen Section or Oily Water Treatment
Section) reach the same degree of completion at the same time, hence some
areas or Sections / units may be mechanically completed while others are not.
It would therefore be a waste of time to wait for the whole WWT plant to be
mechanically completed before starting commissioning activities.

The Start-up sequence of the WWT new plant is driven by operational

constraints where safety equipment and critical utilities are given the highest
priority.
Other utilities and power generation are required earlier than the process
equipment.
Hence, contrary to the construction work progress, which is essentially
planned by trades, areas and equipment tonnage, the optimisation of the start-up
phase goes through the sequential completion of multi-trade operational units:
instrumental air, electric power supply / generation, etc.
In addition, for reasons of optimisation of means and resources, not all
tasks related to Precommissioning, Commissioning disciplines can be
undertaken simultaneously.

Page 9 of 20
 Therefore, the Commissioning planning shall be optimised if the completion
activities are organised not as whole WWTplant activities, but by Operational
Systems and Subsystems

A system is a major subdivision of WWT Plant, being either process or

utility, that performs a major operational function of the plant. The system includes
all the various equipment that allows it to operate.
The instrumental air, service water, electric power supply / generation,
control systems, telecommunications, treated water storage, etc., are typical
examples of systems in WWTP
A subsystem is a further subdivision of a system, that performs a partial
operational function to the system, with no or little interference from the other
subsystems. Several equipment with the same function in the system, main
packages are typical examples of subsystems (Pressure Filters line B, Activated
Carbon Filters line B etc ).
The "system approach" induces the following terminology, related to the
systems, subsystems, and milestones:

• Subsystems are Ready For Commissioning (RFC) when all

Precommissioning activities are complete
• Subsystems are Ready For Start-Up (RFSU) when all
Commissioning activities are complete
• Systems or group of Subsystems are Ready For Operation
(RFO) when all Start-up activities are complete.

Start-Up Team or under Training Operator should pay a particular attention

when the RFSU is issued. This status does not presume that the concerned
sub-system is ready for product in (e.g Oilly Waste water, H2SO4, NaOH, A-
Polymer, C- Polymer etc)

Systems/Sub-systems definition

This specific partition of WWT plant into systems and subsystems for
completions activities takes place as early as possible, prior to Commissioning
Process implementation.
The partition of WWT plant is a key preparation activity for Commissioning
and implicitly to facilitate the structuring of the Beneficiary’s Operators
Training Course into Modules, that has a major impact on all aspects of
completion operation.
The subsystems must be defined so as to be as independent as possible,
not too small, but of manageable size, and exactly adapted to the Start-Up
sequence.
The number of Sub-systems should not ideally be more than 500, but will
depend on the size of the WWTP.
Page 10 of 20
 The basic principle of the completion activities will be to:
• Define, organise, prepare, carry out, report all Precommissioning
and Commissioning activities by systems and subsystems
• The completion activities progress will be reported with a partial
overlapping between systems and subsystems, according to the
Start-up sequence

WITHOUT SYSTEM APPROACH

PRE START INITIAL FUNCTIONAL PERFORMANCE RELIABILITY ROUTINE

COMMISS
COMMISS UP OPERATION TEST TEST TEST OPERATION

WITH SYSTEM APPROACH

PRE
COMMISS

COMMISS

START UP TIME BENEFIT

INITIAL
OPERATION

FUNCTIONAL PERFORMANCE RELIABILITY

TEST TEST TEST

ROUTINE OPERATIO

IFT NON FORMAL TRAINING

OPERATORS TRAINING PROGRAM

Job Shadowing
INFORMAL TRAINING Effective On-the-Job Training
THEORY HANDS ON
Shadowing BSP
CLASSES CLASSES Commissioning Team

3.1.3 Informal Training scheduling

Based on information provided by Beneficiary (number and specialiy job of
the trainees, daily hours when trainees are available for training free of other
duties within their actual job in company, etc) the informal training schedule
should be as follows:
Page 11 of 20
 START INITIAL
PRE COMMISSIONING COMMISSIONING
UP OPERATION
7 days

Consecutive calendaristic days or distributed

INFORMAL TRAINING (46

as practical situation on site request

hours)

3 hours
THEORY CLASSES / day

NON FORMAL CONTINUOS TRAINING

PRACTICAL CLASSES 3 hours (Job Shadowing)
(Hands on – On WWTP site) / day

Trainees
evaluation
4 hours
and
certification

3.1.4 Non formal Training scheduling

There is no specific schedule for informal training. There is valid only the
main schedule for Commissioning activities.The Beneficiary’s operators can
benefit from an informal training through their mere voluntary presence on the
site while BSP Commissioning Team is conducting Commissioning, assisting
BSP's commissioning teams members. Trainees / operators can participate
effective in activities during Reliability tests when they can get responsibilities on
operating the installation

The commissioning activities during the functional tests are full time activities and
run in shifts covering 24h.

In this period of Informal Training the trainees are doing Job Shadowing.

Job shadowing is a type of on-the-job operator job training in which a new

employee or an operator desiring to become familiar with works needed to be
carried on in operating the new Waste Water Treatment Plant, follows and
observes a trained and experienced person from BSP Commissioning Team. Job
shadowing is an effective form of job training for certain jobs specific to the new
WWTP..
Job shadowing allows a trainee operator to gain comprehensive knowledge
about what an employee who holds a particular job does every day. Job
shadowing provides a far richer experience than reading a about what he must
do when operating equipments from WWTP.

Page 12 of 20
 Job shadowing allows the observer to see and understand the nuances of
a particular job. The job shadowing employee is able to observe how the
specialist does the job, the key deliverables expected from the job, and the
employees with whom the job interacts.

Job shadowing is effective when an organization is onboarding a new

employee and when longer term employees want to learn about different jobs in
new plants on train to be operate within the Organization (as WWTP is).
An employee / operator may have expressed interest in doing a new / or
different job, for example operating WWTP installations, but he is not sure about
leaving the tried and true for an uncertain future.

Job shadowing can provide enough information about the new and different
job to allay the employee's fear of the unknown. So, job shadowing is a handy
tool when you want employees to have lateral moves in new commissioned
plants (e.g. WWTP)

Job shadowing is an essential component of any internship experience;

interns need the opportunity to experience a range of jnew obs within their
company while they work in their jobs.
When job shadowing, the individual sees the actual performance of the job
in action. But, in job shadowing, the participant also sees and experiences the
nuances of how the service is provided or the job performed.
The participant experiences the employee’s approach, the interpersonal
interaction required, the steps and actions necessary, and the components
needed to effectively perform the job that the employee might never think to
mention.

While all jobs can have a component of job shadowing as part of their
training and employee development plan, job shadowing is especially effective
for jobs such as these needed in WWTP long term operation.

• Shift supervisors, quality control, field operators, control room operators,

maintenance electrician, instrumentation operator, PLC operator and so
forth.

These examples demonstrate the types of jobs in which learning by job

shadowing is an essential component. But, learning in any job is enhanced by a
component of job shadowing.
Finally, job shadowing becomes essential when an employee is trained
internally for his or next role.

Page 13 of 20
 3.2 TRAINING MODULES OVERVIEW

Module content Adress hours Classes

▪ Safety
MODULE 1 3h theory
▪ Commissioning
To all
Topics: Process
specialities
6h 3h l
Safty&Commissining ▪ Main operations on Hands on
WWTP overview

▪ comprehension of
MODULE 2 waste water treatment 2h theory
Topics: system To all
▪ functional description specialities
6h 2h l
waste water treatment Hands on
system description
▪ Component Systems
overview

- System overview
2h theory
- Normal Waste Water
Pond
- Normal Waste Water
Pumps
- Reaction Tank
- Coagulation Tank
- Clarifier
MODULE 3 - Clarified Water Pond
To all 2h l
Topics: - Thickener
- Dehydrator specialities 4h Hands
Normal Waste Water - Pressure Filters
on
Practical
Treatment System - Activated Carbon Filters on site
- Filtered Water Storage
Tank
- Filter Back Washing
Pump
- Treated Water Pond
- Effluent Pond
- Effluent pump

Page 14 of 20
 Module content Adress hours Classes
- System overview
- Waste Water Holding
MODULE 4 Pond 2h theory
- H2SO4 Tank and acid
Topics: injection systems
To all
-NaOH Tank and NaOH 4h 2h l
Abnormal Waste injection systems specialities
Hands on
Water Treatment - A-Polymer Tank and Hands on
System injection systems Practical
- C- Polymer Tank and on site
injection Systems
- System overview
1h theory
MODULE 5 - Oily Waste Water Pond
- Oil Separator
Topics: - Oily Waste Water Pumps To all 1h l
- Scum Tank (W-006.4.9) specialities 2h Hands on
Oily Waste Water - about reduction of oil Practical
Treatment System contents to 10 mg/l on site
maximum

- Electrical supply
system overview
- Utility systems 6h theory
overview
- Instrument air
- service air
- service water
- electrical power
MODULE 6 - MCC
Topics: - Local control panels
- Inverters
Mainly to
electricians 10h
Utility & MCC - No load tests for 4h l
electric motors Hands on
- Load and run tests for Practical
electric motors on site
- Earthing
- On site illumination
- Maintenance and
troubleshooting on
electric systems /
circuits
Page 15 of 20
 Module content Adress hours Classes
-General Control Panel
overview

Mainly to instrumentation specialists and Control Room

-auxiliary and Main control 6h theory
voltage
-testing operations on
devices manually or by
control
-mechanical and electrical
MODULE 7 interlocks
-regular handling of the
Topics: motor control center

operators
-electrical systems

Instrumentation,
upstream and downstream
of the motor control center
10h 4h l
Control Panels, PLC -Panel mounted Hands on
&HMI instrumentation Practical
-Field mounted on site
instrumentation
-PLC I/O signals
-PLC – HMI comunication
-Operations conducted
from HMI
-Settings and calibration of
Instruments

Evaluation and
Quizzes & answers 4h
Certification

Page 16 of 20
 4. RECORDS for APPLICATION OF THE
TRAINING PROCEDURE
4.1 List of nominated trainees
List of selected (issued by Beneficiay) operational staff to participate to the
Training Program:

Available hours /
Trainee
No.crt Speciality / job position Nominalization day for attending
commitment
training Program

Shift
1.
supervisors

Add as many rows as you consider necessary to fit your selection for personnel to be trained

Control room
2.
operators
Add as many rows as you consider necessary to fit your selection for personnel to be trained

3. Field operators

Add as many rows as you consider necessary to fit your selection for personnel to be trained

Electricians
4. (MCC + field electric motors,
transformers, Invertors, etc)
Add as many rows as you consider necessary to fit your selection for personnel to be trained

5. Instrumentation
specialists
(control panels + field
instrumentation)
Add as many rows as you consider necessary to fit your selection for personnel to be trained

Page 17 of 20
 Maintenance
6. personnel chief
in charge
Add as many rows as you consider necessary to fit your selection for personnel to be trained

7.
PLC – HMI
specialists
Add as many rows as you consider necessary to fit your selection for personnel to be trained

Mechanics
8. Mechanical works
intervention specialists
Add as many rows as you consider necessary to fit your selection for personnel to be trained

9.
Other WWTP
personnel
Add as many rows as you consider necessary to fit your selection for personnel to be trained

Shift
Other WWTP supervisors
personnel

Control room Field Maintenance

operators operators personnel chief in
charge

Electricians Instrumentation
(MCC + field electric
motors,
specialists
transformers, (control panels + field
Invertors, etc) instrumentation)

Mechanical works
PLC – HMI intervention
specialists specialists

Page 18 of 20
 4.2 PRESENCE LIST

Every training session should have a Presence List to track the trainees
participation in the Training Program

Presence list Date:

OPERATORS TRAINING COURSE - WWTP Th. class Hands on
Hours:
Module:
Trainees participants:
Name / surname Speciality Trainee signature

Add as many rows as you consider necessary to fit your trainees number

Page 19 of 20
4.3 FINAL CERTIFICATE ISSUED FOR ALL PARTICIPANTS
IN TRAINING PROGRAM

BLACK SEA POWER GENERATING FZCO

Page 20 of 20