Assessor Resource

PMAOPS304
Operate and monitor compressor systems and equipment

Assessment tool

Version 1.0
Issue Date: May 2024


This unit of competency covers the skills and knowledge required to operate and monitor a complex compressor system. The compressor system will integrate several plant items (single unit operations). Operation of the compressor system includes the operation of ancillary equipment that is integral to the system, such as:

advanced lubrication and seal systems

inter-stage coolers/heat exchangers

scrubbers

surge control systems

instrument/control systems, such as programmable logic controllers (PLCs) or other process controllers.

The competency applies to compressor systems, such as:

single/multi-stage rotary compressors (axial flow, centrifugal, turbine and screw)

single/multi-stage reciprocating compressors.

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 compressor output on the operation of the whole plant and facilitate output changes.

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.

This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members and the control room operator, as appropriate.

This competency 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 compressor system

1.6

Note any outstanding/incomplete work

1.7

Check operational status of compressor system

2

Operate compressor system

2.1

Describe the type of compressor, the component plant items and their duties

2.2

Complete routine checks, logs and paperwork taking action on unexpected readings

2.3

Adjust operational speeds and operating cycles as required

2.4

Monitor or activate safety systems to ensure that any system shutdowns are controlled and conducted safely and effectively

2.5

Adjust compressor system and its component plant items as appropriate to their type and duty to maximise performance

3

Diagnose and take action on abnormal situations in accordance with procedures

3.1

Monitor compressor and its component plant items frequently and critically throughout shift using measured/indicated data and senses

3.2

Monitor impacts of any changes upstream and downstream and take action required by the procedures

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take other actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

3.6

Follow through items initiated until final resolution has occurred

4

Isolate and de-isolate compressor and its component plant items

4.1

Complete any required pre-start checks on compressor and auxiliary systems, including oil and water

4.2

Start up/shut down compressor according to the compressor type and duty in liaison with other personnel

4.3

Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel

4.4

Initiate load-up through the selection of appropriate speed or cycle

4.5

Monitor and adjust upstream/downstream equipment as required

4.6

Isolate entire compressor system and/or any component plant item

4.7

Implement control measures to minimise damage and hazards to/from shutdown compressor

4.8

Make safe for required work

4.9

Check compressor/plant item is ready to be returned to servic

4.10

De-isolate and prepare compressor/plant item 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:

use data and own senses to monitor plant and maximise performance

perform pre-start checks, start-up/shutdown procedures, and isolations and de-isolations

identify early warning signs of equipment/processes needing attention or with potential problems and take required action

isolate the causes of problems and distinguish between causes of problems/alarm/fault indications, including:

process gas variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem

resolve non-routine problems

identify hazards and risks and apply risk control procedures.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the production unit and functions of each

principles of operation of plant/equipment

process specific physics, to the level of being able to interpret the science and extract factors controlling the process and product and production rate and quality (e.g. power and torque envelopes, compression flows and characteristics

interactions between plant items/processes

systems’ operating parameters and integrity limits, product specifications and tolerances, including temperature, pressure and flow

methods of changing flow rate/specifications and the advantages and disadvantages of each

impact of external factors (e.g. variations in weather)

emergency shutdown procedures

function and troubleshooting of major components and their problems and the resolution of these problems

routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions

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.

Where competency has not already been achieved in

PMAOPS221 Operate and monitor prime movers OR

PMAOPS324 Operate a gas turbine

it may be co-delivered and co-assessed.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operations

will typically include a supervisor/third-party report 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 industrial style compressor appropriate to this unit

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 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 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.


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 compressor system

1.6

Note any outstanding/incomplete work

1.7

Check operational status of compressor system

2

Operate compressor system

2.1

Describe the type of compressor, the component plant items and their duties

2.2

Complete routine checks, logs and paperwork taking action on unexpected readings

2.3

Adjust operational speeds and operating cycles as required

2.4

Monitor or activate safety systems to ensure that any system shutdowns are controlled and conducted safely and effectively

2.5

Adjust compressor system and its component plant items as appropriate to their type and duty to maximise performance

3

Diagnose and take action on abnormal situations in accordance with procedures

3.1

Monitor compressor and its component plant items frequently and critically throughout shift using measured/indicated data and senses

3.2

Monitor impacts of any changes upstream and downstream and take action required by the procedures

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take other actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

3.6

Follow through items initiated until final resolution has occurred

4

Isolate and de-isolate compressor and its component plant items

4.1

Complete any required pre-start checks on compressor and auxiliary systems, including oil and water

4.2

Start up/shut down compressor according to the compressor type and duty in liaison with other personnel

4.3

Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel

4.4

Initiate load-up through the selection of appropriate speed or cycle

4.5

Monitor and adjust upstream/downstream equipment as required

4.6

Isolate entire compressor system and/or any component plant item

4.7

Implement control measures to minimise damage and hazards to/from shutdown compressor

4.8

Make safe for required work

4.9

Check compressor/plant item is ready to be returned to servic

4.10

De-isolate and prepare compressor/plant item 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.

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)

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

Situations requiring action

Situations requiring action include one or more of the following:

surging

control of temperature and pressure

variations in feed

vibration

Actions on abnormal situations includes the following:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution.

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person

Start up/shut down

Start up/shut down 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

Procedures

All operations must be performed in accordance with relevant procedures.

Procedures are written, verbal, visual, computer-based or in some other form, 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

Operate

Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or more of the following:

manually in the plant

using local controller in the plant

Product

Product includes anything produced by a process step and so includes:

intermediate products, such as the product from one process step, which then becomes the feed for another

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:

use data and own senses to monitor plant and maximise performance

perform pre-start checks, start-up/shutdown procedures, and isolations and de-isolations

identify early warning signs of equipment/processes needing attention or with potential problems and take required action

isolate the causes of problems and distinguish between causes of problems/alarm/fault indications, including:

process gas variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem

resolve non-routine problems

identify hazards and risks and apply risk control procedures.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the production unit and functions of each

principles of operation of plant/equipment

process specific physics, to the level of being able to interpret the science and extract factors controlling the process and product and production rate and quality (e.g. power and torque envelopes, compression flows and characteristics

interactions between plant items/processes

systems’ operating parameters and integrity limits, product specifications and tolerances, including temperature, pressure and flow

methods of changing flow rate/specifications and the advantages and disadvantages of each

impact of external factors (e.g. variations in weather)

emergency shutdown procedures

function and troubleshooting of major components and their problems and the resolution of these problems

routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions

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.

Where competency has not already been achieved in

PMAOPS221 Operate and monitor prime movers OR

PMAOPS324 Operate a gas turbine

it may be co-delivered and co-assessed.

The collection of performance evidence:

should occur over a range of situations which include typical disruptions to normal, smooth operations

will typically include a supervisor/third-party report 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 industrial style compressor appropriate to this unit

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 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 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.

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
Receive and give shift handover 
Identify work requirements 
Identify and control hazards 
Coordinate with appropriate personnel 
Check for recent work undertaken on compressor system 
Note any outstanding/incomplete work 
Check operational status of compressor system 
Describe the type of compressor, the component plant items and their duties 
Complete routine checks, logs and paperwork taking action on unexpected readings 
Adjust operational speeds and operating cycles as required 
Monitor or activate safety systems to ensure that any system shutdowns are controlled and conducted safely and effectively 
Adjust compressor system and its component plant items as appropriate to their type and duty to maximise performance 
Monitor compressor and its component plant items frequently and critically throughout shift using measured/indicated data and senses 
Monitor impacts of any changes upstream and downstream and take action required by the procedures 
Recognise actual and developing situations which may require action 
Apply operational knowledge to resolve problems 
Take other actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation 
Follow through items initiated until final resolution has occurred 
Complete any required pre-start checks on compressor and auxiliary systems, including oil and water 
Start up/shut down compressor according to the compressor type and duty in liaison with other personnel 
Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel 
Initiate load-up through the selection of appropriate speed or cycle 
Monitor and adjust upstream/downstream equipment as required 
Isolate entire compressor system and/or any component plant item 
Implement control measures to minimise damage and hazards to/from shutdown compressor 
Make safe for required work 
Check compressor/plant item is ready to be returned to servic 
De-isolate and prepare compressor/plant item for return to service 

Forms

Assessment Cover Sheet

PMAOPS304 - Operate and monitor compressor systems and 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

PMAOPS304 - Operate and monitor compressor systems and 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: