Business Challenge

A midstream operator experienced significant turnover at one of its gas plants, resulting in loss of institutional knowledge and inconsistent work practices. The client required new Standard Operating Procedures (SOPs) and a formal Training & Competency Program to ensure that new employees could operate safely, consistently, and efficiently. With limited documentation previously in place, the client needed structured procedure development, risk-based prioritization, and a robust system for demonstrating worker competency.

Objectives & Success Criteria

The client sought to:

• Create clear, accurate, and risk-based Standard Operating Procedures for plant operations.
• Establish a comprehensive Training & Competency Program for onboarding new personnel.
• Identify and prioritize critical tasks through a formal Task Inventory and Task Risk Assessment process.
• Develop competency assessment tools and processes to ensure safe, consistent operations.
• Improve workforce capability, operational consistency, and safety performance.

Success was measured by the completeness of SOPs, clarity of training pathways, worker competency improvements, and feedback from operations leadership.

PMO Solution (What We Did)

PMO applied a structured and industry-proven methodology to rebuild the facility’s operational documentation and workforce competency framework. The process began with developing a Critical Task Inventory and conducting Task Risk Assessments to determine which procedures required priority development, particularly those with high or very high residual risk. PMO then developed detailed, user-friendly SOPs using a standardized procedure development model, ensuring technical accuracy, operational practicality, and clear step-by-step instructions. Procedures underwent stakeholder review, validation, pilot testing, and final approval before being put into effect. Once validated, PMO developed a full Training & Competency Program, including competency profiles, assessment tools, evaluation criteria, and training pathways. The system supports written testing, oral evaluations, and, most importantly, on-the-job assessments conducted by qualified evaluators. The result is a complete, risk-based operational framework enabling consistent training, improved safety outcomes, and long-term workforce development.

Key Components / Activities

• Development of Critical Task Inventory
• Task Risk Assessments for all operational tasks
• Creation of new Standard Operating Procedures (SOPs)
• Procedure review, validation, testing, and approval
• Development of a comprehensive Training & Competency Program
• Creation of competency profiles, assessment tools, and training materials
• On-the-job competency evaluation framework
• Integration of procedures and training into plant operations

Outcomes & Impact

PMO delivered a fully developed suite of SOPs and a Training & Competency Program that significantly strengthened the client’s operational readiness. New staff gained clear, structured training pathways, while supervisors received tools to evaluate and document worker competency. The risk-based approach ensured that the most critical tasks were addressed first, improving safety and operational consistency across the plant. The client now has a sustainable framework for training, competence assurance, and continuous improvement.

Lessons Learned / Challenges Overcome

A key challenge involved building procedures and competency tools from the ground up due to limited pre-existing documentation. PMO overcame this by applying a rigorous task analysis and risk-based prioritization approach. Another lesson learned was the importance of integrating competency assessment with operational reality—ensuring that training tools support real work practices, not theoretical expectations.

Value Proposition Summary

PMO delivered a comprehensive, risk-based operational documentation and competency framework that improved safety, consistency, and workforce capability at a gas plant undergoing major turnover. Through structured SOP development and competency program design, PMO provided the client with a sustainable system for training, evaluation, and operational excellence. This project demonstrates PMO’s ability to support midstream clients in rebuilding workforce capability and operational discipline after significant organizational change.