Assessor Resource

PMAOPS201B
Operate fluid flow equipment

Assessment tool

Version 1.0
Issue Date: March 2024


In a typical scenario, an operator uses a number of general purpose pumps, piping and valves to move liquids from a storage tank area into the processing plant and products to the finished goods tanks. The operator utilises in-line mixers, strainers and filters, valves, controls and meters to complete this work.

The operator would:

identify and report operational problems

be aware of and contribute to a safe working environment

contribute to the safe and productive operation of the equipment

operate, monitor and maintain equipment using relevant procedures.

Generally the operator would be part of a team during start up and shut down procedures and would be expected to be capable of demonstrating competence in all parts of this unit. At all times they would be liaising and cooperating with other members of the team.

This unit does not require the operation of a central control panel.

This competency covers all general duty pumps, their associated drivers (motors) and valves. It does not cover special duty pumps (eg hydrocarbon transmission pumps), drivers which incorporate ancillaries and valves which are used for high pressure/flow situations (see PMAOPS221 Operate and monitor prime movers, PMAOPS222B Operate and monitor pumping systems and equipment and PMAOPS223B Operate and monitor valve systems). Competence in this unit (PMAOPS20B 1 Operate fluid flow equipment) would preclude counting PMAOPS223B Operate and monitor valve systems towards a qualification.

This competency covers the operation of the range of pumps and valves typically encountered in the fluid flow system of a processing plant. It includes identifying, operating, monitoring and troubleshooting these items.

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Employability Skills

This unit contains employability skills.




Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment of this unit should include demonstrated competence on actual plant and equipment in a work environment. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation may be required to allow for assessment of parts of this unit. Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

This unit of competency requires a significant body of knowledge which will be assessed through questioning and the use of what-if scenarios both on the plant (during demonstration of normal operations and walk throughs of abnormal operations) and off the plant.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action. The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

early warning signs of equipment/processes needing attention or with potential problems are recognised

the range of possible causes can be identified and analysed and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems in related plant areas are recognised and an appropriate contribution made to their solution.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations which may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with units covering:

measurements and readings

housekeeping

communication.

In a major hazard facility, it may be appropriate to assess this unit concurrently with:

MSAPMOHS200A Work safely.

The assessment should cover at least one type of centrifugal pump and one type of positive displacement pump, as well as at least two different types of valves for the operator to be regarded as competent.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, language and literacy capacity of the assessee and the work being performed.


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving.

Required knowledge

Competence includes an understanding of the fluid flow system and its integral equipment to a level needed to control the system, and recognise and resolve operational problems. In particular it includes a knowledge of:

principles of operation of plant/equipment

physics and chemistry relevant to the process unit

process parameters and limits eg temperature, pressure, flow, pH

duty of care obligations

hierarchy of control

communication protocols eg radio, phone, computer, paper, permissions/authorities

routine problems, faults and their resolution

relevant alarms and actions

plant process idiosyncrasies

all items on a schematic of the fluid flow system and the function of each

correct methods of starting, stopping, operating and controlling flow

causes of head loss in piping systems (including comparison of fittings using Le/d concept, fluid and pipe material properties, flow geometry, etc)

corrective action appropriate to the problem cause

function and troubleshooting of major internal components and their problems (such as impellors, seals or bearings)

types and causes of fluid flow problems within operator's scope of skill level and responsibility.

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the Performance Criteria, is detailed below. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

This competency is typically performed by all operators. It includes items of equipment such as:

pumps, including various types of centrifugal, positive displacement, acid egg

valves, such as globe, needle, gate, butterfly, plug cock, wedge plug, ball cock, non-return, diaphragm, pneumatic globe, pneumatic butterfly

piping systems and components, including bends and elbows, tee pieces, expansion mechanisms, pipe joints, reducers, nipples, orifices, in-line mixers, filters and strainers, flexible hoses and couplings

shaft seals, such as stuffing boxes, mechanical seals, fluid seals, labyrinth seals.

The effect of pipe fittings on pump performance and problems/problem analysis is also included.

All operations are performed to procedures.

Problems

Typical problems include:

cavitation

seal leaks

head loss/low flow

bearing problems.

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person.

Procedures

Procedures may be written, verbal, computer-based or in some other form. They include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.

Start up shut down as required

Start up shut down as required includes:

start up and shut down to/from normal operating conditions

start up and shut down to/from isolated, cold, empty

all other conditions experienced on the plant.

ie from any condition to any condition experienced on the plant.

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Identify work requirements 
Identify and control hazards 
Coordinate with appropriate personnel 
Identify the type of pump 
Start up and shut down pump as required 
Adjust flow and head/pressure as appropriate to type of pump 
Complete routine checks and reports taking action as required 
Change over pumps as required. 
Monitor critical variables such as amps, temperature and vibration 
Keep critical variables in range 
Recognise trends/patterns which indicate a potential or actual problem with the pump driver 
Take action to ensure driver as required. 
Identify the type of valve 
Operate valve in a manner appropriate to the valve type 
Complete routine checks and reports, taking action as required. 
Monitor fluid flow system frequently and critically throughout shift using measured/indicated data and senses (sight, hearing, etc) as appropriate 
Recognise issues requiring action 
Take appropriate action. 
Isolate equipment 
Make safe for required work 
Check plant is ready to be returned to service 
Prepare plant for return to service . 

Forms

Assessment Cover Sheet

PMAOPS201B - Operate fluid flow equipment
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

PMAOPS201B - Operate fluid flow equipment

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

Date: