Industrial Resources, Inc.

TYPICAL IRI PROJECTS

IRI assisted the Power Plant in implementing a comprehensive modular based Plant Operator Training Program by developing the plant specific System Training Modules and an Operator Training Plan.

Each plant specific System Training Module package consisted of the following:

System Description

System Operating Procedure

Review Questions

OJT Training Checklists

OJT Training Guide

A Training Plan for Plant Operator Training Program was also provided. The Training Plan was designed to establish the training process. The process ensured that all operators have the knowledge and skills to successfully perform their jobs and that the process is uniform for all. The plan also provides for administration of the program and details the process for implementing and performing the training.

IRI developed student workbooks for three plant turbine generator sets and provided on-site instruction. The instruction took place over six training sessions, scheduled consecutively over a two week period. The three Albright training sessions were for two days each. The three Fort Martin training sessions were one day each. The student workbooks were designed for use as training tools for training plant operators and are used to complement each training session.

Lovett and Bowline Power Plants (Mirant)

IRI provided an on-site instructor to present power plant training at the Lovett and Bowline Power Station. The Training focused on four systems, Sootblowing, Mills, Precips and Turbine/Seal Oil. The IRI instructor using reference materials provided Lovett Power Station developed all training materials.

Crawfordsville Electric Light and Power Plant Operational and Maintenance Improvement

IRI provided professional services to improve operational and maintenance effectiveness of the plant. The services provided were designed to develop the internal resources of the Crawfordsville Power Plant personnel with the objective of improving plant heat rate, improving peak equipment availability, prepare your company to be completive in the market and to provide better service and continuity of service to the customers. This was accomplished by:

El Paso Electric
Training and Development Program

IRI is currently assisting El Paso Electric Rio Grande and Newman Power Stations in implementing a comprehensive modular based Plant Operator Training Program by developing the plant specific System Training Modules. The training materials developed for these modules are designed to support the training requirements as listed in the El Paso Electric Operator Training Plan.

Each plant System Training Module package will consist of the following:

IRI is also providing on-site instructors to implement the training process. These instructors will present training classes on basic power plant theory as well as plant specific system and procedures training.

PacifiCorp Thermal – Power Plant Operator Training and Certification Program

IRI developed and assisted in implementing a complete Power Plant Operator Training and Certification Program at all PacifiCorp Power Generating Stations: Wyodak, Jim Bridger, Dave Johnson, Naughton, Little Mountain, Blundell, Gadbsy, Carbon, Huntington and Hunter. The plants ranged from large coal and gas fired units to combustion turbines and geothermal. The project also included developing and validating a training plan for each plant, a training needs assessment for each operator, individualized training plans, plant specific training materials including plant operating procedures and plant specific testing and evaluation materials including job performance measures.

IRI developed and assisted in implementing a complete Hydro Plant Operator Training Program at over 65 PacifiCorp Hydro Electric Generating Stations located throughout the Northwest. The plants range from large manned plants to small remotely operated systems. The project included developing a training plan for each plant, providing a training needs assessment for each operator and preparing individualized training plans, developing plant specific training materials including plant operating procedures, and providing plant specific testing and evaluation materials with job performance measures.

IRI validated the lineman and serviceman, substation technician and meter technician training qualification requirements for several CSW companies including; West Texas Utilities (WTU) Southwestern Electric Power Company (SWEPCO) and Central Power and Light (CP&L). The validation was performed using the Job Content method utilizing Subject Matter Expert questionnaires, which were computer analyzed to determine the validity of each training and qualification item in terms of job content.

IRI presented a variety of short custom training courses both on-site and at IRI facilities to meet specific customer needs. These courses include:

As part of a legal requirement to improve performance evaluation procedures, IRI developed a series of task performance measures for use in evaluating all PEPCO operations personnel. This included preparing final qualification books for plant operators, coal and ash operators, laboratory technicians, fuels technicians, motor repairers, instrument repairer, steam path mechanic, plant mechanic, mechanical/production services, tool keeper, certified welder, plant clerk among others. Qualification books were developed for all of PEPCO's plants and the production center.

Mirant – Birchwood and Stateline Power Plant Operator
Training and Certification Program

To manage the training effort IRI provided computer-based training management programs (Training Tracker and Safety Tracker) and trained plant personnel in the use of the programs. To ensure that future training provided by the plant staff was efficient and effective, a Train-the-Trainer program was presented to all potential instructors.

IRI developed and presented Boiler Operator Training and Certification Program designed to provide boiler plant operators with the knowledge and skills necessary to operate a steam boiler safely and efficiently. Pre and posttest were used to determine the focus of instruction to evaluate student accomplishment of course objectives. At the completion of the course, an examiner tested the students for licensing as Power Engineers. IRI performed this work under a multi-year contract to provide this training program for the Department of Defense worldwide.

IRI developed and presented a series of on-site training program for electric utility companies throughout the Caribbean. Training programs included Training Systems Management, Transportation Fleet Management and Capital Recovery and Cost Depreciation. The training was provided as a complete package with the teaching materials, the instructor and a student test.

IRI developed a Hands-on Training Program, which involved training welders, mechanics, assistant mechanics, utility workers and group supervisors to remove and replace pipe insulation material in the generating stations. The training was provided as a complete package that included an instructor with over 20 years experience as an insulation installer. Insulation tools/material/equipment needed to conduct the training were provided as part of the program.

IRI developed and assisted in implementing a 38-month Basic Electronics Training Program designed to train up to 720 electronics workers. This included developing a training plan to accomplish the training programs goals, preparing the course curriculum, selecting training materials, developing a pre-screening test to be used to prepare individual training plans and arranging to have the program accredited by community and technical colleges throughout the eastern United States. The program presented a particular challenge in that the trainees are distributed over a large geographical area and could not be brought together for classroom training except on an occasional basis. To meet this need a combination of home study using video-based training materials and an instructor led review and evaluation session were used. The instructor led sessions are presented and accredited at various community colleges throughout the client’s area.

IRI reviewed existing NISCO startup and shutdown procedures and plant technical manuals. A format for new procedures was then developed that included photographs of plant equipment, valves and controls used in startup and shutdown. The Procedures were then prepared and provided to NISCO on a CD-ROM in a format that could be easily modified and revised as needed.

IRI developed a comprehensive Safe Boiler Operating Program for Central South West (CSW) power plants. The training program was developed as a complete package that included all necessary training materials needed to present a four (4) hour training program on safe boiler operation. Specific items that were provided include:

Facilitators Guide for presenting the training

Training Viewgraphs (Transparencies)

Student Text with CSW plant-specific information

The overall objective of developing the deliverables as listed above was to support a four-hour training course to be presented by CSW instructors at each plant. It was a comprehensive training program designed to upgrade the knowledge, skills and abilities of plant operating personnel to safely operate CSW boilers.

IRI develops and presents customized on-site instructor training programs that are designed specifically to teach technical instructors to use job/task analysis methods to develop, present and evaluate technical training programs. As part of the training programs, each trainee uses job/task analysis procedures to develop a model-training program. The instructor training is being presented on a continuing basis at electric utilities throughout the United States.

Bogue Power Center – Montego Bay, Jamaica
Operator Training and Certification Program

Grand Bahamas Power Plant - Kingston, Grand Bahamas Operation and Certification Program

IRI developed a complete Training and Certification Program that included defining job requirements for plant operators and developing a comprehensive training plan that would integrate generic training materials provided by other vendors with plant specific procedures, job performance measures and written exams prepared by IRI. The program included operator training and certification requirements for operation of three gas fired boiler units, two simple cycle gas turbine plants and a large diesel-generating unit. IRI provided unit specific operating procedures, training materials, training plans for each individual operator, a series of job performance measures and written exams designed to evaluate operator capability to operate the plant equipment.

IRI developed a complete Training and Certification Program that included defining job requirements for plant operators and developing a comprehensive training plan that would integrate generic training materials provided by other vendors with plant specific procedures, job performance measures and written exams prepared by IRI. The plant specific materials developed by IRI included system descriptions with graphic illustrations and pictures of plant equipment, detailed operating procedures and job performance measures for evaluating plant operator competency.

IRI developed plant specific training materials that included system descriptions, system operating procedures, job performance measures and written exams for three units. These units used a variety of fuels including coal, oil and gas. The completed materials have been integrated into a training and certification program for plant operators using both plant specific training materials and generic training materials provided by other vendors.

Kendall Power Plant - Cambridge, MA

Combined Cycle Combustion Turbine Training and Certification Program

IRI developed a complete Training and Certification Program for a large gas fired combined cycle combustion turbine plant. This included developing plant specific operating procedures and training materials as well as unit integrated operation procedures for operating the HRSG and combustion turbine in relation to the other conventionally fired boilers in the plant.

IRI developed a complete Training and Certification Program that included defining job requirements for plant operators and developing a comprehensive training plan that would integrate generic training materials provided by other vendors with plant specific procedures, job performance measures and written exams prepared by IRI. The program included training and certification requirements for operators for three coal fired units and two combined cycle HRSG combustion turbine units. The plant specific materials developed by IRI included system descriptions with graphic illustrations and pictures of plant equipment, detailed operating procedures and job performance measures for evaluating plant operator competency. IRI also provided evaluation test items in a computerized test bank and training managementsoftware for administering the program.

Franklin Heating Station – Rochester, MN
Operator Training Manuals

IRI developed a comprehensive training program for plant operators of a large steam heating and cooling plant that provides critical services to the Mayo Clinic. The services provided consisted of developing a series of training manuals and operating procedures for plant operating and distribution systems. These manuals and operating procedures included plant specific drawings, graphics and photos designed to enhance the learning process.

PPL Montana Power, Colstrip Power Plant, Colstrip, MT
System Description and Operating Procedures

IRI updated and rewrote the plant’s systems descriptions and operating procedures. This included revising to reflect plant updates and modifications, enhancing the documents by adding graphics, photographs and illustrations. The plant is a large coal fired plant with multiple units.

IRI developed a complete Training and Certification Program for plant operators that included defining job requirements, developing a comprehensive training plan that would integrate generic training materials provided by other vendors with plant specific procedures, job performance measures and written exams prepared by IRI. The program included training and certification requirements for operators for two coal fired boiler units. As part of the project IRI updated the systems descriptions and operating procedures for Units 7 and 8 that included graphic illustrations and pictures of plant equipment, updated operating procedures and job performance measures for evaluating plant operator competency.

American Electric Power Line Mechanical Training Center

IRI has developed a complete training curriculum outline for the Line Mechanical Training Center. This outline is designed to provide structure for the training courses offered by AEP and to provide a qualification path for line mechanic certification.

CVC BOO Plant Curacao, Netherlands
Operating Procedures