Master of EducationOn the 25th September 1998 two plant operators were killed and a further eight operators were seriously injured when the Longford Gas Plant exploded and caught on fire. The Royal Commission that followed this disaster identified inadequate operator training and operator incompetence as a significant causal factor that contributed to this disaster. This study investigates the nature of process plant operator competence in the petrochemical industry in the `post Longford' environment.
This study used qualitative research methods to study operator competence, specifically document analysis and in-depth interviews with plant operators and training managers. Data from the document analysis and interview transcripts were collected and analysed with a view to improving understanding of the factors that contribute to operator competence.
The findings of this study indicated that operator competence involves formal learning and also informal and tacit knowledge that is learnt in `communities of practice' where experienced operators mentor and guide less experienced members of the shift team. This study suggests that genuine operator competence involves more than just an ability to manage routine duties but also involves an ability to respond effectively during non-routine situations and plant emergencies - these crises have the potential for catastrophic consequences if poorly managed. This study found that there are significant opportunities to improve the training strategies and the organisational support structures to enhance operator competence.
This study has made a number of recommendations to improve the competence of petrochemical plant operators. A theoretical model has also been developed to enhance plant operator competence in the petrochemical industry. Suggestions for future research into the area of plant operator competence have been suggested
