Unit of Competency Mapping – Information for Teachers/Assessors – Information for Learners

PMAOPS202 Mapping and Delivery Guide
Operate fluid mixing equipment

Version 1.0
Issue Date: April 2024


Qualification -
Unit of Competency PMAOPS202 - Operate fluid mixing equipment
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to operate fluid mixers found in fluid processing plants. This unit of competency applies to operators who are required to operate, monitor and maintain equipment using relevant procedures and contribute to a safe working environment. This unit of competency is typically performed by all operators using mixing equipment. 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.In a typical scenario an operator uses a baffled mixing tank (or other mixer) to make a product to specification. This covers the loading of liquid and perhaps solid materials into the mixing equipment. In this example the operator monitors the mixing to ensure the components are dispersed appropriately and checks the resulting product to ensure it complies.This unit of competency covers the mixing of two or more materials to make a product. This may be achieved through various means ranging from continuous mixing processes as typically found in oil plants to batch mixing as commonly used in chemical plants and paint manufacture. No licensing, legislative or certification requirements apply to this unit at the time of publication.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.

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

‘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
Prerequisites/co-requisites
Competency Field Operations
Development and validation strategy and guide for assessors and learners Student Learning Resources Handouts
Activities 		Slides
PPT 		Assessment 1 Assessment 2 Assessment 3 Assessment 4
Elements of Competency Performance Criteria              
Element: Prepare for work
  • Receive and give shift handover
  • Identify work requirements
  • Identify and control hazards
  • Coordinate with appropriate personnel
  • Check for recent work undertaken on plant item
  • Note any outstanding/incomplete work
  • Check operational status of fluid mixing equipment
       
Element: Prepare mixing equipment
  • Identify type of fluid mixer
  • Identify appropriate applications for the mixer type
  • Check materials
       
Element: Operate fluid mixing equipment in accordance with procedures
  • Charge materials
  • Start up/shut down fluid mixing equipment
  • Adjust mixing conditions
  • Check product
  • Adjust product as instructed or to procedure
  • Discharge product
  • Complete routine checks and reports, taking action on unexpected readings and trends
       
Element: Recognise and take appropriate action on abnormal situations
  • Monitor fluid mixing equipment frequently and critically throughout shift using measured/indicated data and senses
  • Identify impacts of any changes upstream and downstream
  • Recognise situations which may require action
  • Resolve routine problems
  • Take actions in accordance with procedures on other abnormal situations to make safe and have the situation resolved
       
Element: Isolate and de-isolate equipment
  • Complete any required pre-start checks
  • Start up/shut down/changeover fluid mixing equipment according to the equipment type and duty in liaison with other personnel
  • Isolate plant
  • Make safe for required work
  • Check plant is ready to be returned to service
  • De-isolate and prepare plant for return to service
       


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 fluid mixing equipment

2

Prepare mixing equipment

2.1

Identify type of fluid mixer

2.2

Identify appropriate applications for the mixer type

2.3

Check materials

3

Operate fluid mixing equipment in accordance with procedures

3.1

Charge materials

3.2

Start up/shut down fluid mixing equipment

3.3

Adjust mixing conditions

3.4

Check product

3.5

Adjust product as instructed or to procedure

3.6

Discharge product

3.7

Complete routine checks and reports, taking action on unexpected readings and trends

4

Recognise and take appropriate action on abnormal situations

4.1

Monitor fluid mixing equipment frequently and critically throughout shift using measured/indicated data and senses

4.2

Identify impacts of any changes upstream and downstream

4.3

Recognise situations which may require action

4.4

Resolve routine problems

4.5

Take actions in accordance with procedures on other abnormal situations to make safe and have the situation resolved

5

Isolate and de-isolate equipment

5.1

Complete any required pre-start checks

5.2

Start up/shut down/changeover fluid mixing equipment according to the equipment type and duty in liaison with other personnel

5.3

Isolate plant

5.4

Make safe for required work

5.5

Check plant is ready to be returned to service

5.6

De-isolate and prepare plant 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 demonstrate the ability to:

apply pre-start, start-up and shutdown procedures

monitor and operate mixing 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.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the mixing system and the function of each

fluid mixing principles including shear, viscosity and concepts of uniformity

principles of operation of fluid mixing equipment

physics of operation

correct methods of starting, stopping, operating and controlling mixing equipment

typical mixing problems, and their causes and remedy, within operator’s scope of skill level and responsibility

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

their possible causes

potential consequences

appropriate risk controls

environmental requirements related to waste disposal

relevant alarms and actions

plant process idiosyncrasies

routine problems, faults and their resolution

function and troubleshooting of major components and their problems

corrective action appropriate to the problem cause

communication protocols (e.g. radio, phone, computer, paper and permissions/authorities).

Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assignment, 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 fluid mixing equipment

2

Prepare mixing equipment

2.1

Identify type of fluid mixer

2.2

Identify appropriate applications for the mixer type

2.3

Check materials

3

Operate fluid mixing equipment in accordance with procedures

3.1

Charge materials

3.2

Start up/shut down fluid mixing equipment

3.3

Adjust mixing conditions

3.4

Check product

3.5

Adjust product as instructed or to procedure

3.6

Discharge product

3.7

Complete routine checks and reports, taking action on unexpected readings and trends

4

Recognise and take appropriate action on abnormal situations

4.1

Monitor fluid mixing equipment frequently and critically throughout shift using measured/indicated data and senses

4.2

Identify impacts of any changes upstream and downstream

4.3

Recognise situations which may require action

4.4

Resolve routine problems

4.5

Take actions in accordance with procedures on other abnormal situations to make safe and have the situation resolved

5

Isolate and de-isolate equipment

5.1

Complete any required pre-start checks

5.2

Start up/shut down/changeover fluid mixing equipment according to the equipment type and duty in liaison with other personnel

5.3

Isolate plant

5.4

Make safe for required work

5.5

Check plant is ready to be returned to service

5.6

De-isolate and prepare plant 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:

smoke, darkness and heat

dust or other atmospheric hazards

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 or other atmospheric hazards

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

Equipment

Equipment includes one or more of the following:

mixers for low, medium and high viscosity fluids

jet mixing

top and side entry mixers

propeller, and pitched and square bladed turbine impellers

Routine problems

Routine problems must be resolved by applying known solutions.

Routine problems are predictable and include one or more of the following:

incorrect mixing time

incorrect power consumption

uniformity issues

vortexing

aeration

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.

Resolve routine problems

Resolving routine problems includes changing one or more of the following:

position and angle of baffles where appropriate

impellor (angle, size, shape or speed)

feed rate of fluids

Mixing conditions

Mixing conditions will be adjusted by one or more of the following:

baffles

mixer speed

mixing duration

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 on abnormal situations

Action on abnormal situations 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

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

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

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 plant item 
Note any outstanding/incomplete work 
Check operational status of fluid mixing equipment 
Identify type of fluid mixer 
Identify appropriate applications for the mixer type 
Check materials 
Charge materials 
Start up/shut down fluid mixing equipment 
Adjust mixing conditions 
Check product 
Adjust product as instructed or to procedure 
Discharge product 
Complete routine checks and reports, taking action on unexpected readings and trends 
Monitor fluid mixing equipment frequently and critically throughout shift using measured/indicated data and senses 
Identify impacts of any changes upstream and downstream 
Recognise situations which may require action 
Resolve routine problems 
Take actions in accordance with procedures on other abnormal situations to make safe and have the situation resolved 
Complete any required pre-start checks 
Start up/shut down/changeover fluid mixing equipment according to the equipment type and duty in liaison with other personnel 
Isolate plant 
Make safe for required work 
Check plant is ready to be returned to service 
De-isolate and prepare plant for return to service 

Forms

Assessment Cover Sheet

PMAOPS202 - Operate fluid mixing 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

PMAOPS202 - Operate fluid mixing 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: