PMA40108 Certificate IV in Process Plant Technology

Revision Number: 3

PMA40108 Certificate IV in Process Plant Technology

Modification History

Release 3 - MEM elective unit code corrected: MEM11011B

Release 2 - Addition of new electives: PMASUP244A, PMASUP444A, NWP357B

Description

The Certificate IV in Process Plant Technology has been developed as a technical qualification for use in the Chemical, Hydrocarbons and Refining Training Package (PMA08).

Job roles/employment outcomes

The Certificate IV in Process Plant Technology is intended for plant technicians.

The technician will typically be involved in solving complex problems which require theoretical knowledge, combined with an understanding of the production process and equipment across the plant.

Application

This qualification is typically used to develop employees performing a technical role that includes an ability to work independently and conduct technical problem solving according to the needs of the work in the manufactured mineral products industries.

Non-technical team leaders, coordinators and supervisors may be better served by a qualification in competitive manufacturing. The Certificate IV in Competitive Manufacturing MCM40104 is available for team leaders at this level where the job requires sophisticated manufacturing practice skills rather than technical skills.

People with this qualification may be expected to work in one of the following sectors:

fine chemicals

heavy chemicals

petrochemicals

polymer manufacture

hydrocarbon extraction

hydrocarbon transmission

hydrocarbon processing/refining

minerals processing/refining

metals smelting/processing

other related areas.

Training programs for this qualification are suitable to be undertaken as part of a formal training contract with an employer under an Australian Traineeship or Apprenticeship arrangement.

Pathways Information

Pathways into the qualification

This qualification may be accessed by direct entry. Credit may be granted towards this qualification by those who have completed PMA30110 Certificate III in Process Plant Operation, MSA30107 Certificate III in Process Manufacturing, MSA30208 Certificate III in Manufacturing Technology or other relevant qualifications. Credit for this qualification may also include units contained within relevant skill sets.

Pathways from the qualification

Further training pathways from this qualification include PMA50110 Diploma of Process Plant Technology, MSA51108 Diploma of Competitive Manufacturing, MSA50108 Diploma of Manufacturing Technology or other relevant qualifications, including appropriate vocational graduate qualifications.

Additional qualification advice

MSA41108 Certificate IV in Competitive Manufacturing is available for team leaders at this level who already possess technical skills and who require additional manufacturing practice skills above those available in this qualification.

Licensing/Regulatory Information

There are no specific licences that relate to this qualification. However, in some jurisdictions some units of competency in this qualification may have licensing or regulatory requirements. Local regulations should be checked for details.

Entry Requirements

Not applicable.

Employability Skills Summary

Employability Skill	Industry/enterprise requirements for this qualification include:
Communication	maintain communication about multiple subjects and with multiple audiences complete incident and other reports communicate technical information update workplace documentation maintain workplace records
Teamwork	identify and describe own role and role of other assist others identify role lead team teams either formally or on an ad hoc basis resolve conflicts between teams
Problem-solving	recognise persistent problems or those not definable by direct observation. determine problems needing priority action. investigate and analyse problems and potential solutions. work with technical experts to define problems and develop possible solutions apply appropriate theory base for problem follow through items initiated until final resolution has occurred. identify and isolate faults in entire plant use a range of formal problem solving techniques
Initiative and enterprise	proactive in fine tuning of entire plant seeks out areas requiring improvement anticipate the impact of the process on customers and value chain members
Planning and organising	prioritise actions to achieve required outcomes for plant plan work requirements for plant plan plant maintenance or shutdowns/turnarounds identify tasks to achieve plant goals. allocate tasks. monitor completion of allocated tasks develop and adjust schedules
Self-management	plan own work requirements from plant requirements operate within appropriate time constraints and work standards select and use appropriate techniques identify resource requirements, document and monitor recognise limitations and seek timely advice
Learning	maintain and develop own competency assist others to develop their required competencies lead improvement procedures/strategies
Technology	improvements to and fine tuning of entire process start up and shut down planning and coordinating a shut down/start up of plant solving of problems not directly observable monitor product/process quality function and operating principles of unit, system or plant area maintain workplace records

Packaging Rules

To be awarded the Certificate IV in Process Plant Technology competency must be achieved in twenty six (26) units of competency: five (5) core units of competency twenty one (21) elective units of competency hosen as specified below. Note Where prerequisite units apply, these must be considered in the total number of units chosen.
Core units of competency
Unit code	Unit title
MSAENV272B	Participate in environmentally sustainable work practices
MSAPMOHS110A	Follow emergency response procedures
MSAPMOHS200A	Work safely
MSAPMSUP100A	Apply workplace procedures
MSAPMSUP102A	Communicate in the workplace
Elective units of competency
Select twenty one (21) units as specified below: A minimum of one (1) from Group A The remainder may be chosen from Groups A, B and C (with a maximum of eighteen (18) from Group C) to bring the total number of electives to twenty one (21). Note that up to five (5) units can be chosen from other qualifications in this Training Package, other endorsed Training Packages and accredited courses, as specified in Groups B and C.
Group A – Specialist electives
Unit code	Unit title	Prerequisites
MSAPMOPS400A	Optimise process/plant area	MSAPMSUP390A
MSAPMOPS401A	Trial new process product
PMAOPS402A	Respond to abnormal process situations	MSAPMSUP390A
PMAOPS405A	Operate complex control systems
PMAOPS410B	Monitor remote production facilities
PMAOPS411B	Manage plant shutdown and restart
PMAOPS433A	Manage wells and gathering systems
PMAOPS434A	Commission wells and gathering systems
PMAOPS450B	Solve colour problems
One (1) unit may be chosen from Group A in PMA50110 Diploma of Process Plant Technology
Group B
Unit code	Unit title	Prerequisites
MSACMC411A	Lead a competitive manufacturing team
MSACMC413A	Lead team culture improvement
MSACMS401A	Ensure process improvements are sustained
MSACMT430A	Improve cost factors in work practices
MSACMT440A	Lead 5S in a manufacturing environment
MSACMT441A	Facilitate continuous improvement in manufacturing
MSACMT450A	Undertake process capability improvements	MSACMT452A
MSACMT451A	Mistake proof a production process
MSACMT452A	Apply statistics to processes in manufacturing
MSACMT460A	Facilitate the use of planning software systems in manufacturing	MSACMT260A
MSACMT481A	Undertake proactive maintenance analyses
MSACMT482A	Assist in implementing a proactive maintenance strategy
MSAENV472B	Implement and monitor environmentally sustainable work practices
MSAPMOHS400A	Contribute to workplace OHS management system	MSAPMOHS300A
MSAPMOHS401A	Assess risk
MSAPMOPS404A	Co-ordinate maintenance
MSAPMOPS405A	Identify problems in fluid power system
MSAPMOPS406A	Identify problems in electronic control systems
MSAPMPER400A	Coordinate permit process	MSAPMPER300C
MSAPMSUP400A	Develop and monitor quality systems
MSL954001A	Obtain representative samples in accordance with a sampling plan
PMAOHS420B	Develop first aid procedures and manage resources
PMAOMIR407B	Audit incident preparedness and established response system
PMAOMIR418B	Coordinate incident response
PMAOMIR424B	Develop and maintain community relationships
PMAOMIR430B	Conduct and assess incident exercises
PMAOMIR444B	Develop incident containment tactics
PMAOMIR449B	Monitor legal compliance obligations during incidents
PMASUP410B	Develop plant documentation
PMASUP420B	Minimise environmental impact of process
PMASUP432B	Coordinate pipeline projects
PMASUP440B	Commission/recommission plant
PMASUP441C	Decommission plant
PMASUP444A	Plan plant preparation and isolation
PMASUP445A	Participate in HAZOP studies	PMAOPS280A
TAEASS401A	Plan assessment activities and processes
TAEASS402A	Assess competence
TAEASS403A	Participate in assessment validation
Up to one (1) relevant unit may be chosen from this Training Package, other endorsed Training Packages and accredited courses, where that unit is available at Certificate IV or Diploma.
Group C
Unit code	Unit title	Prerequisites
FDFPHGMP1A	Follow work procedures to maintain Good Manufacturing Practice
FDFPHGMP2B	Implement Good Manufacturing Practice procedures
FDFPHGMP3A	Monitor the implementation of Good Manufacturing Practice procedures
MEM05012C	Perform routine manual metal arc welding
MEM07033B	Operate and monitor basic boiler
MEM07034A	Operate and monitor intermediate class boiler	MEM07033B
MEM09002B	Interpret technical drawing
MEM09003B	Prepare basic engineering drawing	MEM09002B
MEM11011B	Undertake manual handling
MEM16005A	Operate as a team member to conduct manufacturing, engineering or related activities
MEM18011C	Shutdown and isolate machines/equipment
MSACMS201A	Sustain process improvements
MSACMT230A	Apply cost factors to work practices
MSACMT231A	Interpret product costs in terms of customer requirements
MSACMT240A	Apply 5S procedures in a manufacturing environment
MSACMT250A	Monitor process capability
MSACMT251A	Apply quality standards
MSACMT260A	Use planning software systems in manufacturing
MSACMT270A	Use sustainable energy practices
MSACMT271A	Use sustainable environmental practices
MSACMT280A	Undertake root cause analysis
MSACMT281A	Contribute to the application of a proactive maintenance strategy
MSAPMOHS100A	Follow OHS procedures
MSAPMOHS205A	Control minor incidents
MSAPMOHS210B	Undertake first response to non-fire incidents
MSAPMOHS212A	Undertake first response to fire incidents
MSAPMOHS216A	Operate breathing apparatus
MSAPMOHS217A	Gas test atmospheres
MSAPMOHS220A	Provide initial first aid response
MSAPMOHS300A	Facilitate the implementation of OHS for a work group
MSAPMOPS100A	Use equipment
MSAPMOPS102A	Perform tasks to support production
MSAPMOPS200A	Operate equipment
MSAPMOPS212A	Use enterprise computers or data systems
MSAPMPER200C	Work in accordance with an issued permit
MSAPMPER201A	Monitor and control work permits
MSAPMPER202A	Observe permit work
MSAPMPER205C	Enter confined space
MSAPMPER300C	Issue work permits	RIIRIS201A
MSAPMSUP101A	Clean workplace or equipment
MSAPMSUP106A	Work in a team
MSAPMSUP172A	Identify and minimise environmental hazards
MSAPMSUP200A	Achieve work outcomes
MSAPMSUP201A	Receive or despatch goods
MSAPMSUP204A	Pack products or materials
MSAPMSUP205A	Transfer loads
MSAPMSUP210A	Process and record information
MSAPMSUP240A	Undertake minor maintenance
MSAPMSUP280A	Manage conflict at work
MSAPMSUP291A	Participate in continuous improvement
MSAPMSUP292A	Sample and test materials and product
MSAPMSUP300A	Identify and implement opportunities to maximise production efficiencies	MSAPMSUP200A
MSAPMSUP301A	Apply HACCP to the workplace
MSAPMSUP303A	Identify equipment faults
MSAPMSUP309A	Maintain and organise workplace records
MSAPMSUP310A	Contribute to development of plant documentation
MSAPMSUP330A	Develop and adjust a production schedule
MSAPMSUP382A	Provide coaching/mentoring in the workplace
MSAPMSUP383A	Facilitate a team
MSAPMSUP390A	Use structured problem solving tools
MSL952001A	Collect routine site samples
MSL973001A	Perform basic tests
NWP357B	Monitor, operate and control reverse osmosis and nano-filtration processes
PMAOHS211B	Prepare equipment for emergency response
PMAOHS213B	Undertake fire control and emergency rescue
PMAOHS214B	Undertake helicopter safety and escape
PMAOHS215B	Apply offshore facility abandonment and sea survival procedures
PMAOHS221B	Maintain first aid supplies and records
PMAOHS310B	Investigate incidents
PMAOHS311B	Lead emergency teams
PMAOHS312B	Command the operation of survival craft
PMAOHS320C	Provide advanced first aid response
PMAOHS321B	Provide first aid response in remote and/or isolated area
PMAOMIR210B	Control evacuation to muster point
PMAOMIR301B	Undertake initial rescue
PMAOMIR302B	Respond to a helideck incident
PMAOMIR317B	Facilitate search and rescue operations
PMAOMIR320B	Manage incident response information
PMAOMIR321B	Manage communication systems during an incident
PMAOMIR346B	Assess and secure an incident site
PMAOPS101C	Read dials and indicators
PMAOPS105C	Select and prepare materials
PMAOPS201B	Operate fluid flow equipment
PMAOPS202B	Operate fluid mixing equipment
PMAOPS203B	Handle goods
PMAOPS204B	Use utilities and services
PMAOPS205B	Operate heat exchangers
PMAOPS206B	Operate separation equipment
PMAOPS207B	Operate powered separation equipment
PMAOPS208B	Operate chemical separation equipment
PMAOPS210B	Operate particulates handling equipment
PMAOPS211B	Operate manufacturing extruders
PMAOPS213B	Package product/material
PMAOPS216B	Operate local control system
PMAOPS217B	Operate wet milling equipment
PMAOPS220B	Monitor chemical reactions in the process
PMAOPS221B	Operate and monitor prime movers
PMAOPS222B	Operate and monitor pumping systems and equipment	Co-requisite unit PMAOPS221B
PMAOPS223B	Operate and monitor valve systems
PMAOPS224B	Provide fluids for utilities and support
PMAOPS230B	Monitor, operate and maintain pipeline stations and equipment
PMAOPS231B	Control gas odourisation
PMAOPS232B	Produce product by filtration
PMAOPS233A	Monitor wells and gathering systems
PMAOPS234A	Monitor and operate low pressure compressors
PMAOPS240B	Store liquids in bulk
PMAOPS241A	Operate Joule-Thomson effect device
PMAOPS280B	Interpret process plant schematics
PMAOPS290B	Operate a biotreater
PMAOPS300B	Operate a production unit
PMAOPS301B	Produce products by distillation	PMAOPS201B Co-requisite PMAOPS205B
PMAOPS302B	Operate reactors and reaction equipment
PMAOPS303B	Operate furnaces to induce reaction
PMAOPS304B	Operate and monitor compressor systems and equipment	Co-requisite unit PMAOPS221B
PMAOPS305B	Operate process control systems
PMAOPS307B	Transfer bulk fluids into/out of storage facility	PMAOPS201B
PMAOPS308B	Organise storage and logistics of general materials
PMAOPS309B	Operate particulates handling/ storage equipment
PMAOPS312B	Undertake ship loading/unloading operations
PMAOPS319A	Adjust batch
PMAOPS320B	Conduct artificial lift
PMAOPS321B	Undertake well management
PMAOPS323A	Operate and monitor heating furnace
PMAOPS324A	Operate a gas turbine
PMAOPS325B	Generate electrical power
PMAOPS326B	Produce product using gas absorption
PMAOPS327B	Produce product using fixed bed dehydration
PMAOPS329B	Produce product using liquid extraction
PMAOPS330B	Communicate pipeline control centre operations
PMAOPS333A	Operate wells and gathering systems
PMAOPS335A	Conduct pipeline pigging
PMAOPS340B	Operate cryogenic processes
PMAOPS350B	Match and adjust colour
PMAOPS390B	Operate a biochemical process
PMASMELT260B	Form carbon anodes
PMASMELT261B	Bake carbon anodes
PMASMELT262B	Clean and strip anode rods
PMASMELT263B	Spray carbon anodes
PMASMELT264B	Start up reduction cells
PMASMELT265B	Operate reduction cells
PMASMELT266B	Deliver molten metal
PMASMELT267B	Cast aluminium ingots
PMASMELT268B	Vertical direct casting
PMASMELT269A	Operate cell tending equipment
PMASMELT270A	Supply product from reduction cells
PMASUP236B	Operate vehicles in the field
PMASUP237B	Undertake crane, dogging and load transfer operations
PMASUP241B	Maintain pipeline easements
PMASUP242B	Monitor pipeline civil works
PMASUP243B	Monitor and maintain pipeline coatings
PMASUP244A	Prepare and isolate plant
PMASUP305A	Operate offshore cranes
PMASUP311A	Operate communications hub
PMASUP341B	Monitor and maintain instrument and control systems	MSAPMPER300C
PMASUP342B	Monitor and maintain electrical systems	MSAPMPER300C
PMASUP343B	Monitor and maintain cathodic protection systems
PMASUP344B	Monitor and control repairs and modifications on operational pipe
PMASUP345A	Monitor vibration
PMASUP346A	Control corrosion
PMASUP347A	Undertake corrosion inspection in a petrochemical environment
PSPGOV308B	Work effectively with diversity
RIIOHS204A	Work safely at heights
RIIRIS201A	Conduct local risk control
TAEASS301A	Contribute to assessment
TAEDEL301A	Provide work skill instruction
TLID1007C	Operate a forklift
UEPOPS319A	Operate and Monitor Gas Production Plant
UEPOPS340A	Operate and Monitor a Steam Turbine
Up to four (4) relevant units may be chosen from this Training Package, other endorsed Training Packages and accredited courses where those units are available at Certificates III and IV.