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

PMAOPS301 Mapping and Delivery Guide
Operate a distillation unit

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMAOPS301 - Operate a distillation unit
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to monitor and control a distillation unit, which is separating two or more components, to achieve finished product that meets a predetermined specification. The distillation column may be trayed or packed and may be performing cryogenic gas distillation, liquid distillation, azeotropic distillation, fractional distillation, vacuum distillation or molten metal distillation.This unit of competency applies to operations technicians who are required to identify and correct operational problems, determine the impact of composition changes and adjust accordingly, and direct members of the operational team under start-up and running conditions.In a typical scenario an operations technician would be monitoring and controlling the distillation section of a plant from a central control room. The process may involve one or more distillation columns and their associated equipment, piping and 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 appropriateThis competency does not require the operation of a central control panel. Operators undertaking this unit of competency should also be competent in operating fluid flow equipment andheat exchangers.Competency in this unit requires the ability to integrate the operation of all the component parts as a whole.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.

Where competency has not already been achieved in

PMAOPS201 Operate fluid flow equipment

PMAOPS205 Operate heat exchangers

they 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 operation of an industrial style distillation unit

may use industry-based simulation for all or part 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.
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 the distillation unit
  • Note any outstanding/incomplete work
  • Check operational status of distillation unit and its component units
       
Element: Operate distillation unit
  • Describe the type of distillation unit, the component plant items and their duties
  • Complete routine checks, logs and paperwork taking appropriate action on unexpected readings
  • Change rate, grade or specification smoothly as required
  • Adjust distillation unit and its component plant items as appropriate to their type and duty to maximise performance
       
Element: Diagnose and take appropriate action on abnormal situations
  • Monitor distillation unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses as appropriate
  • Describe impacts of any changes upstream and downstream
  • Recognise actual and developing situations which may require action
  • Apply operational knowledge to resolve problems
  • Take other appropriate 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
       
Element: Isolate and de-isolate distillation unit and its component plant items
  • Complete any required pre-start checks
  • Start up/shut down distillation unit according to its 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
  • Isolate entire distillation unit and/or any component plant item
  • Make safe for required work
  • Check distillation unit /plant item is ready to be returned to service
  • De-isolate and prepare distillation unit /plant item 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 the distillation unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of distillation unit and its component units

2

Operate distillation unit

2.1

Describe the type of distillation unit, the component plant items and their duties

2.2

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

2.3

Change rate, grade or specification smoothly as required

2.4

Adjust distillation unit and its component plant items as appropriate to their type and duty to maximise performance

3

Diagnose and take appropriate action on abnormal situations

3.1

Monitor distillation unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses as appropriate

3.2

Describe impacts of any changes upstream and downstream

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take other appropriate 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 distillation unit and its component plant items

4.1

Complete any required pre-start checks

4.2

Start up/shut down distillation unit according to its 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

Isolate entire distillation unit and/or any component plant item

4.5

Make safe for required work

4.6

Check distillation unit /plant item is ready to be returned to service

4.7

De-isolate and prepare distillation unit /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 the ability to:

start up, and stabilise the components of the distillation system to meet specifications

apply process knowledge to monitor and predict the need for adjustments to system components

predict impact of a change in one unit/area on other plant units/areas and take appropriate action

identify hazards and risks and apply risk control procedures

communicate effectively with team, group, supervisors and other personnel

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

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

process feed variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem

resolve non-routine problems

take appropriate action to ensure a timely return to full performance.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the distillation unit and the function of each

principles of operation of plant/equipment, including column, tray/packing, condensor and reboiler operations, and distillation principles, including stripping and rectification

interactions between plant items/processes

systems’ operating parameters and limits, such as temperature, pressure, flow and system integrity limits

methods of changing production rate, product specifications and process variables

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

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

process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality (e.g. for chemistry interpret the equation for factors controlling rate and yield and also interfering reactions such as salts and hydrates)

hierarchy of control

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

their possible causes

potential consequences

appropriate risk controls.

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 the distillation unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of distillation unit and its component units

2

Operate distillation unit

2.1

Describe the type of distillation unit, the component plant items and their duties

2.2

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

2.3

Change rate, grade or specification smoothly as required

2.4

Adjust distillation unit and its component plant items as appropriate to their type and duty to maximise performance

3

Diagnose and take appropriate action on abnormal situations

3.1

Monitor distillation unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses as appropriate

3.2

Describe impacts of any changes upstream and downstream

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take other appropriate 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 distillation unit and its component plant items

4.1

Complete any required pre-start checks

4.2

Start up/shut down distillation unit according to its 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

Isolate entire distillation unit and/or any component plant item

4.5

Make safe for required work

4.6

Check distillation unit /plant item is ready to be returned to service

4.7

De-isolate and prepare distillation unit /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 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

Non-routine problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

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

Non-routine problems are unexpected problems, or variations of previous problems and include one or more of the following:

recognising and acting on unstable/sub-optimal operation, such as:

flooding

channelling (packed column)

dumping

entrainment

control of critical variables and outputs

variations in feed rates and/or quality

Operational knowledge includes one or more of the following:

procedures

training

technical information, such as journals and engineering specifications

remembered experience

relevant knowledge obtained from appropriate people

Appropriate actions on abnormal situations

Appropriate actions 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

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

Distillation unit

This unit of competency includes all such items of equipment and unit operations which form part of the distillation system. A unit comprises two or more components of plant/equipment that are operated together to produce product, including as appropriate to the facility:

columns/towers

trays/packing

boilers/reboilers

condensers

refrigerant compressors

pumps

valves

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 the distillation unit 
Note any outstanding/incomplete work 
Check operational status of distillation unit and its component units 
Describe the type of distillation unit, the component plant items and their duties 
Complete routine checks, logs and paperwork taking appropriate action on unexpected readings 
Change rate, grade or specification smoothly as required 
Adjust distillation unit and its component plant items as appropriate to their type and duty to maximise performance 
Monitor distillation unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses as appropriate 
Describe impacts of any changes upstream and downstream 
Recognise actual and developing situations which may require action 
Apply operational knowledge to resolve problems 
Take other appropriate 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 
Start up/shut down distillation unit according to its 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 
Isolate entire distillation unit and/or any component plant item 
Make safe for required work 
Check distillation unit /plant item is ready to be returned to service 
De-isolate and prepare distillation unit /plant item for return to service 

Forms

Assessment Cover Sheet

PMAOPS301 - Operate a distillation unit
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

PMAOPS301 - Operate a distillation unit

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: