PMAOPS217 - Operate wet milling equipment assessment tool

Assessor Resource

PMAOPS217
Operate wet milling equipment

Assessment tool

Version 1.0
Issue Date: May 2024

This unit of competency covers the skills and knowledge required to operate wet milling equipment and its ancillary equipment.

Wet milling equipment is used in plants that manufacture paint and other materials. The wet milling equipment may be vertical or horizontal mills and may incorporate rolls, balls or beads as the milling medium.

This unit of competency applies to operators who are required to start up and shut down the equipment, process monitoring and planning for maintenance, contribute to optimisation, and identify operational problems and take appropriate action.

This unit of competency applies to an individual who may work alone although under routine direction and supervision. They may work as part of a team or group and will work in liaison with other shift team members and the control room operator, as appropriate.

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

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

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

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.

Elements describe the essential outcomes.		Performance criteria describe the performance needed to demonstrate achievement of the element.
1	Prepare for work	1.1	Receive and give shift handover
		1.2	Identify work requirements
		1.3	Identify and control hazards
		1.4	Coordinate with appropriate personnel
		1.5	Check for recent work undertaken on plant item
		1.6	Note any outstanding/incomplete work
		1.7	Check operational status of equipment

2	Operate mill in accordance with procedures	2.1	Identify the type of wet mill and duty
		2.2	Complete routine checks, logs and paperwork taking appropriate action on unexpected readings
		2.3	Adjust mill, as appropriate to type and duty
		2.4	Change rate, grade or specification smoothly

3	Recognise and take action on abnormal situations in accordance with procedures	3.1	Monitor mill operating condition frequently and critically throughout shift using measured/indicated data and senses
		3.2	Identify impacts of any changes upstream and downstream
		3.3	Recognise situations which may require action
		3.4	Resolve routine problems
		3.5	Take actions on other abnormal situations to make safe and have the situation resolved

4	Isolate and de-isolate equipment	4.1	Complete any required pre-start checks
		4.2	Confirm raw materials are available and correct
		4.3	Prepare pre-mixer and introduce raw materials to pre-mixer if required
		4.4	Start up/shut down wet mill according to plant type and duty in liaison with other personnel
		4.5	Isolate wet mill
		4.6	Make safe for required work
		4.7	Check wet mill is ready to be returned to service
		4.8	De-isolate and prepare wet mill for return to service

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

start up and shut down wet mill equipment

monitor and operate wet mill equipment to meet specifications

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

determine the most likely cause of routine problems

take appropriate action to ensure a timely return to full performance

isolate and de-isolate equipment

identify hazards and apply hazard control procedures.

Hazards include one or more of the following:

principles of operation of milling equipment

process and product variables

bead/ball/rod life (if used in process)

physics and chemistry relevant to the process unit

process parameters and limits, e.g. temperature, pressure, flow and pH

routine problems, faults and their resolution

relevant alarms and actions

correct methods of starting, stopping, operating and controlling mill

function and troubleshooting of major components and their problems

hierarchy of control

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

their possible causes

potential consequences

appropriate risk controls.

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 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

â€˜what ifsâ€™.

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 must demonstrate both technical competency and currency. If the assessor cannot demonstrate technical competency and currency they must 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 organisationâ€™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

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.

Elements describe the essential outcomes.		Performance criteria describe the performance needed to demonstrate achievement of the element.
1	Prepare for work	1.1	Receive and give shift handover
		1.2	Identify work requirements
		1.3	Identify and control hazards
		1.4	Coordinate with appropriate personnel
		1.5	Check for recent work undertaken on plant item
		1.6	Note any outstanding/incomplete work
		1.7	Check operational status of equipment

2	Operate mill in accordance with procedures	2.1	Identify the type of wet mill and duty
		2.2	Complete routine checks, logs and paperwork taking appropriate action on unexpected readings
		2.3	Adjust mill, as appropriate to type and duty
		2.4	Change rate, grade or specification smoothly

3	Recognise and take action on abnormal situations in accordance with procedures	3.1	Monitor mill operating condition frequently and critically throughout shift using measured/indicated data and senses
		3.2	Identify impacts of any changes upstream and downstream
		3.3	Recognise situations which may require action
		3.4	Resolve routine problems
		3.5	Take actions on other abnormal situations to make safe and have the situation resolved

4	Isolate and de-isolate equipment	4.1	Complete any required pre-start checks
		4.2	Confirm raw materials are available and correct
		4.3	Prepare pre-mixer and introduce raw materials to pre-mixer if required
		4.4	Start up/shut down wet mill according to plant type and duty in liaison with other personnel
		4.5	Isolate wet mill
		4.6	Make safe for required work
		4.7	Check wet mill is ready to be returned to service
		4.8	De-isolate and prepare wet mill for return to service

This field allows for different work environments and conditions that may affect performance. Essential operating conditions that may be present (depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts) are included.
Regulatory framework	The latest version of all legislation, regulations, industry codes of practice and Australian/international standards, or the version specified by the local regulatory authority, must be used, and include one or more of the following: legislative requirements, including work health and safety (WHS) industry codes of practice and guidelines environmental regulations and guidelines Australian and other standards licence and certification requirements All operations to which this unit applies are subject to stringent health, safety and environment (HSE) requirements, which may be imposed through state/territory 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.
Procedures	All operations must be performed in accordance with relevant procedures. Procedures are written, verbal, visual, computer-based or in some other form, and include one or more of the following: emergency procedures work instructions standard operating procedures (SOPs) safe work method statements (SWMS) formulas/recipes batch sheets temporary instructions any similar instructions provided for the smooth running of the plant
Hazards	Hazards include one or more of the following: electricity gas gases and liquids under pressure structural hazards structural collapse equipment failures industrial (machinery, equipment and product) equipment or product mass noise, rotational equipment or vibration plant services (steam, condensate and cooling water) limited head spaces or overhangs working at heights, in restricted or confined spaces, or in environments subjected to heat, noise, dusts or vapours flammability and explosivity hazardous products and materials unauthorised personnel sharp edges, protrusions or obstructions slippery surfaces, spills or leaks extreme weather other hazards that might arise
Routine problems	Routine problems must be resolved by applying known solutions. Routine problems are predictable and include one or more of the following: condition and life of beads condition of rollers/balls cooling system fouling blocked filters or piping high/low levels loss of process cooling resulting in high process temperatures equipment failure or shutdown resulting in loss of feed to process excess/unexpected sand production composition changes Known solutions are drawn from one or more of the following: procedures training remembered experience Non-routine problems must be reported according to according to relevant procedures.
Start up/shut down as required	Start up/shut down as required includes the following: start up and shut down to/from normal operating conditions start up and shut down to/from isolated, cold or empty start up and shut down to/from other conditions/situations experienced on the plant
Action	Action in accordance with procedures includes the following: 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
Operate	Operate is to monitor, adjust/change the plant item/unit/system to meet specifications, by one or more of the following: manually in the plant using local controller in the plant using the process control system in the control room
Wet milling equipment	Wet milling equipment will be selected as required from the following: vertical horizontal bead mills roll/ball-type mills
Ancillary equipment	Ancillary equipment includes one or more of the following: pre-mix vessels coolers, cooling jackets and heat exchangers pumps vessels, tanks piping systems valves and flanges sumps and drains