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

PMAOPS301B Mapping and Delivery Guide
Produce product by distillation

Version 1.0
Issue Date: March 2024


Qualification -
Unit of Competency PMAOPS301B - Produce product by distillation
Description This unit covers the monitoring and controlling of a distillation unit, which is separating two or more components to achieve finished product, which meets a predetermined specification. The process may or may not be controlled from a central control room.
Employability Skills This unit contains employability skills.
Learning Outcomes and Application 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.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.Each tower may be provided with:reboiler/heaterfeed at an appropriate temperatureover head product condenserreflux equipmenttower internalsinstrumentation.The operations technician will be able to:identify and correct operational problemsdetermine the impact of composition changes and adjust accordinglydirect members of the operational team under start-up and running conditions.Generally the operations technician 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.
Duration and Setting X weeks, nominally xx hours, delivered in a classroom/online/blended learning setting.
Prerequisites/co-requisites PMAOPS201B Operate fluid flow equipmentPMAOPS205B Operate heat exchangers
Competency Field
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.
  • Identify work requirements
  • Identify and control hazards
  • Coordinate with appropriate personnel
       
Element: Start up distillation system.
  • Perform pre-start up checks
  • Bring into operation equipment required for distillation
  • Correctly sequence all equipment required before commencing the process
  • Monitor temperature increase during start up and take appropriate action
  • Stabilise distillation system to produce specified rate and quality within minimum time.
       
Element: Monitor distillation process.
  • Continually monitor process systems to ensure that product specifications are maintained
  • Minimise the risk of product specification deviations during the process by applying process knowledge
  • Adjust process variables to ensure the product remains within specification
  • Identify issues likely to impact on plant performance and take appropriate action
  • Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people
  • Record product movements as a historical record of the quantity and quality of the finished product.
       
Element: Change production rates and/or product specification.
  • Predict the need to make change to meet process requirements
  • Manipulate unit temperatures to achieve product specifications
  • Trim plant in a manner which prepares it for the transition
  • Manage transitions smoothly and in a timely manner
  • Minimise out of specification material as a result of a transition.
       
Element: Shut down distillation systems.
  • Determine type of shut down required
  • Give advanced warning of shut down where possible
  • Change over individual items of equipment
  • Shut down individual items of equipment and the entire reaction system
  • Shut down to a stand-by condition if required
  • Shut down in an emergency when required
  • Reset trips and alarms after a shut down
  • Leave plant in a condition ready to restart
  • Make plant safe for maintenance work where required.
       
Element: Prepare distillation unit for maintenance.
  • Inform plant personnel of impending maintenance activity
  • Prepare unit for maintenance/vessel entry as required according to procedures
  • Test trips and alarms as required
  • Accept plant back from maintenance
  • Prepare plant for the introduction of process materials and operation.
       


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, role plays and 3D virtual reality interactive systems. In the case of evacuation training or of training for competencies practised in life threatening situations, simulation may be used for the bulk of the training.

This unit of competency requires an application of the knowledge contained in the use of distillation units and their integral equipment, to the level needed to maintain control and recognise and resolve problems. This can 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:

PMAOPS201B Operate fluid flow equipment

PMAOPS222B Operate and monitor pumping systems and equipment

PMAOPS205B Operate heat exchangers.

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

MSAPMOHS200A Work safely.

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, 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.

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

Required skills

Competence includes:

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving.

Competence also includes the ability to isolate the causes of problems to an item of equipment within the distillation system and to distinguish between causes of problems/alarm/fault indications such as:

process feed variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem.

Required knowledge

The knowledge referred to in the Evidence Guide for this unit includes:

principles of operation of plant/equipment

physics and chemistry relevant to the process unit and the materials processed

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

process control philosophies and strategies

outside process/production operations, including column, tray/packing and reboiler operations, and distillation principles (including stripping and rectification)

heating and cooling principles

stabilisation principles

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 plant item and the function of each

correct methods of starting, stopping, operating and controlling process

corrective action appropriate to the problem cause

function and troubleshooting of major components and their problems

types and causes of 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 of 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.

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.

Context

This unit of competency includes all such items of equipment and unit operations which form part of the distillation system. For your plant this may include (select relevant items):

columns/towers

trays/packing

boilers/reboilers

condensers

heat exchangers

refrigerant compressors

pumps

valves.

Typical problems for your plant may include:

flooding

channelling (packed column)

dumping

entrainment.

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.

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 
Perform pre-start up checks 
Bring into operation equipment required for distillation 
Correctly sequence all equipment required before commencing the process 
Monitor temperature increase during start up and take appropriate action 
Stabilise distillation system to produce specified rate and quality within minimum time. 
Continually monitor process systems to ensure that product specifications are maintained 
Minimise the risk of product specification deviations during the process by applying process knowledge 
Adjust process variables to ensure the product remains within specification 
Identify issues likely to impact on plant performance and take appropriate action 
Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people 
Record product movements as a historical record of the quantity and quality of the finished product. 
Predict the need to make change to meet process requirements 
Manipulate unit temperatures to achieve product specifications 
Trim plant in a manner which prepares it for the transition 
Manage transitions smoothly and in a timely manner 
Minimise out of specification material as a result of a transition. 
Determine type of shut down required 
Give advanced warning of shut down where possible 
Change over individual items of equipment 
Shut down individual items of equipment and the entire reaction system 
Shut down to a stand-by condition if required 
Shut down in an emergency when required 
Reset trips and alarms after a shut down 
Leave plant in a condition ready to restart 
Make plant safe for maintenance work where required. 
Inform plant personnel of impending maintenance activity 
Prepare unit for maintenance/vessel entry as required according to procedures 
Test trips and alarms as required 
Accept plant back from maintenance 
Prepare plant for the introduction of process materials and operation. 

Forms

Assessment Cover Sheet

PMAOPS301B - Produce product by distillation
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

PMAOPS301B - Produce product by distillation

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: