Unit of competency

Modification History

Release 1. Supersedes and is equivalent to PMAOPS300B Operate a production unit

Application

This unit of competency covers the skills and knowledge required to operate an enterprise-specific unit of a production plant, which is not otherwise described by other units in this Training Package. The production unit operation will integrate several plant items (single unit operations). For the operation of a single unit operation refer to the relevant PMAOPS2## unit of competency.

This unit of competency applies to operations technicians who are required to demonstrate a significant understanding of the process and the equipment operation in order to identify and rectify operational problems, predict the potential impact of the production unit output on the operation of the whole plant, and facilitate output changes.

Operation of the production unit includes the operation of other plant items which are integral to the operation of the production unit.

This unit of competency applies to an individual operating independently in a plant with local control, or in liaison with the control room operator in a plant with a centralised control panel, such as distributed control system (DCS) type controls. In the case of large complex plant, the operations technician would be part of a team during start-up and shutdown procedures.

The operations technician is expected to be capable of performing all parts of this unit of competency. At all times they would be liaising and cooperating with other members of the team.

No licensing, legislative or certification requirements apply to this unit at the time of publication.

Pre-requisite Unit

Nil

Competency Field

Operations

Unit Sector

Elements and Performance Criteria

Foundation Skills

This section describes those language, literacy, numeracy and employment skills that are essential to performance.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range of Conditions

Unit Mapping Information

Release 1. Supersedes and is equivalent to PMAOPS300B Operate a production unit

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=9fc2cf53-e570-4e9f-ad6a-b228ffdb6875

Assessment requirements

Modification History

Release 1. Supersedes and is equivalent to PMAOPS300B Operate a production unit

Performance Evidence

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and demonstrate the ability to:

• identify and control hazards
• use data and own senses to monitor plant and maximise performance
• isolate the causes of problems to an item of equipment within the production unit and to distinguish between causes of problems/alarm/fault indications, including:

• process materials variations
• instrument failure/wrong reading
• electrical failure
• mechanical failure
• operational problem

• recognise early warning signs of equipment/processes needing attention or with potential problems
• take appropriate action to ensure a timely return to full performance
• perform pre-start checks, start-up/shutdown procedures and isolations and de-isolations
• complete written records
• communicate effectively with team or group, supervisors and other personnel
• identify and communicate information required by others.

Knowledge Evidence

Evidence must be provided that demonstrates knowledge of:

• organisation procedures
• hazards that may arise in the job/work environment, and:

• their possible causes
• potential consequences
• appropriate risk controls

• all items on a schematic of the production unit and the function of each
• the basis of the process used in the production unit to transform the feed materials into the product
• process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality (e.g. for chemistry interpret the equation for factors controlling rate and yield and also interfering reactions, such as salts and hydrates)
• interactions between plant items/processes
• basic science of upstream and downstream processes
• product specifications and tolerances
• systems’ operating parameters
• impact of external factors (e.g. variations in weather and feed)
• system integrity limits
• emergency shutdown procedures
• routine and non-routine problems that may arise, and the range of possible causes and processes to develop solutions
• methods of changing rate/grade/specification or feed and the advantages and disadvantages of each
• principles of operation of plant/equipment
• plant process idiosyncrasies
• correct methods of starting, stopping, operating and controlling
• isolation procedures
• process parameters and limits (e.g. temperature, pressure, flow, pH and amps)
• effects of variations in process conditions and materials
• required preparation and permits required for different types of work to be done on the production unit or its component items.

Assessment Conditions

• The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.
• The collection of performance evidence:

• should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant
• will typically include a supervisor/third-party report or other evidence, focusing on consistent performance and problem recognition and solving. A supervisor/third-party report must be prepared by someone who has a direct, relevant, current relationship with the person being assessed and who is in a position to form a judgement on workplace performance relevant to the unit of competency
• must include the use of an appropriate industrial item of equipment requiring demonstration of operation, start-up and shutdown procedures and responding to problems
• may use industry-based simulation for part only of the unit particularly where safety, lack of opportunity or significant cost is an issue.

• Assessment should occur in operational workplace situations. Where this is not possible, or where personal safety or environmental damage are limiting factors, assessment must occur in a sufficiently rigorous simulated environment reflecting realistic operational workplace conditions. This must cover all aspects of workplace performance, including environment, task skills, task management skills, contingency management skills and job role environment skills.
• Assessment in a simulated environment should use evidence collected from one or more of:

• walk-throughs
• pilot plant operation
• demonstration of skills
• industry based case studies/scenarios
• ‘what ifs’.

• Knowledge evidence may be collected concurrently with performance evidence (provided a record is kept) or through an independent process, such as workbooks, written assessments or interviews (provided a record is kept).
• Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.
• Conditions for assessment must include access to all tools, equipment, materials and documentation required, including relevant workplace procedures, product and manufacturing specifications associated with this unit.
• The regulatory framework will be reflected in workplace policies and procedures and is not required to be independently assessed.
• Foundation skills are integral to competent performance of the unit and should not be assessed separately.
• Assessors must satisfy the assessor competency requirements that are in place at the time of the assessment as set by the VET regulator.
• In addition the assessor or anyone acting in subject matter expert role in assessment shall demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they shall assess with a subject matter expert who does meet these requirements.
• Technical competence can be demonstrated through one or more of:

• relevant VET or other qualification/Statement of Attainment
• appropriate workplace experience undertaking the type of work being assessed under routine and non-routine conditions
• appropriate workplace experience supervising/ evaluating the type of work being assessed under routine and non-routine conditions.

• Currency can be demonstrated through one or more of:

• being currently employed undertaking the type of work being assessed
• being employed by the organisation undertaking the type of work being assessed and having maintained currency in accordance with that organisation’s policies and procedures
• having consulted/had contact with an organisation undertaking the type of work being assessed within the last twelve months, the consultation/contact being related to assessment
• conducting on-the-job training/assessments of the type of work being assessed
• being an active member of a relevant professional body and participating in activities relevant to the assessment of this type of work.

Links

Companion Volume implementation guides are found in VETNet - https://vetnet.gov.au/Pages/TrainingDocs.aspx?q=9fc2cf53-e570-4e9f-ad6a-b228ffdb6875