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

PMAOPS390 Mapping and Delivery Guide
Operate a biochemical process

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMAOPS390 - Operate a biochemical process
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to operate a biochemical process and ancillary equipment to produce chemical or biological materials as product. It applies to biochemical processes that use enzymes, such as amylases; moulds, such as yeasts; and/or bacteria, such as e coli. It applies to batch and continuous processes.Products could include industrial alcohol, corn starch, insulin or other industrial fermentation/biochemical processes. This unit applies to the biochemical conversion plant unit.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 changes from other plant sections on biochemical process, 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. In the case of large complex plant, the operations technician would be part of a team during start-up and shutdown procedures. 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 unit of 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.
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 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 type biochemical process and equipment allowing operation

may use industry-based simulation for 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 biochemical unit
  • Note any outstanding/incomplete work
  • Check operational status of biochemical unit
       
Element: Operate the biochemical processes
  • Describe the type of biochemical plant unit, the component plant items and their duties
  • Complete routine checks, logs and paperwork
  • Check performance of all ancillaries (such as mixing and heat exchange)
  • Recognise and interpret trends in bioreactor data/appearance
  • Recognise the signs of potential and actual problems
  • Identify the consequences to the bioreactor processes of the identified changes, trends and problems
  • Keep conditions within the optimum range
  • Take action to minimise the impact on health, safety and environment (HSE) and the business of potential and actual problems
       
Element: Ramp output up/down
  • Predict from rates and schedule when a change will be required
  • Give advanced notice of change to work team
  • Prepare plant for the change
  • Predict the required amount of adjustment to cause the required change
  • Make the change in a controlled manner without excessive variation
  • Monitor the progress of the change and make minor adjustments as required
       
Element: Diagnose and take action on abnormal situations in accordance with procedures
  • Monitor biochemical unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses.
  • 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 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 biochemical unit and its component plant items
  • Complete any required pre-start checks
  • Start up/shut down biochemical 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 biochemical unit and/or any component plant item
  • Make safe for required work
  • Check biochemical unit/plant item is ready to be returned to service
  • De-isolate and prepare biochemical unit/plant item for return to service
       
Element: Clean reactors/vessels
  • Identify cleaning requirements
  • Clean to requirements according to procedures
  • Retain microorganisms contained in the plant and prepare for reuse as appropriate
  • Dispose of waste materials according to procedures
       


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 biochemical unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of biochemical unit

2

Operate the biochemical processes

2.1

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

2.2

Complete routine checks, logs and paperwork

2.3

Check performance of all ancillaries (such as mixing and heat exchange)

2.4

Recognise and interpret trends in bioreactor data/appearance

2.5

Recognise the signs of potential and actual problems

2.6

Identify the consequences to the bioreactor processes of the identified changes, trends and problems

2.7

Keep conditions within the optimum range

2.8

Take action to minimise the impact on health, safety and environment (HSE) and the business of potential and actual problems

3

Ramp output up/down

3.1

Predict from rates and schedule when a change will be required

3.2

Give advanced notice of change to work team

3.3

Prepare plant for the change

3.4

Predict the required amount of adjustment to cause the required change

3.5

Make the change in a controlled manner without excessive variation

3.6

Monitor the progress of the change and make minor adjustments as required

4

Diagnose and take action on abnormal situations in accordance with procedures

4.1

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

4.2

Describe impacts of any changes upstream and downstream

4.3

Recognise actual and developing situations which may require action

4.4

Apply operational knowledge to resolve problems

4.5

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

4.6

Follow through items initiated until final resolution has occurred

5

Isolate and de-isolate biochemical unit and its component plant items

5.1

Complete any required pre-start checks

5.2

Start up/shut down biochemical unit according to its type and duty in liaison with other personnel

5.3

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

5.4

Isolate entire biochemical unit and/or any component plant item

5.5

Make safe for required work

5.6

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

5.7

De-isolate and prepare biochemical unit/plant item for return to service

6

Clean reactors/vessels

6.1

Identify cleaning requirements

6.2

Clean to requirements according to procedures

6.3

Retain microorganisms contained in the plant and prepare for reuse as appropriate

6.4

Dispose of waste materials according to procedures

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

adjust processes parameters to meet product requirements

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

identify hazards and risks and apply risk control procedures.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the system and functions of each

principles of operation of biochemical process and ancillary equipment

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

systems’ operating parameters, integrity limits, including feed, desired output, temperature, agitation, aeration (if appropriate), microorganism/enzyme, product tolerances, and impact of external factors (e.g. variations in weather and feed)

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.

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 biochemical unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of biochemical unit

2

Operate the biochemical processes

2.1

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

2.2

Complete routine checks, logs and paperwork

2.3

Check performance of all ancillaries (such as mixing and heat exchange)

2.4

Recognise and interpret trends in bioreactor data/appearance

2.5

Recognise the signs of potential and actual problems

2.6

Identify the consequences to the bioreactor processes of the identified changes, trends and problems

2.7

Keep conditions within the optimum range

2.8

Take action to minimise the impact on health, safety and environment (HSE) and the business of potential and actual problems

3

Ramp output up/down

3.1

Predict from rates and schedule when a change will be required

3.2

Give advanced notice of change to work team

3.3

Prepare plant for the change

3.4

Predict the required amount of adjustment to cause the required change

3.5

Make the change in a controlled manner without excessive variation

3.6

Monitor the progress of the change and make minor adjustments as required

4

Diagnose and take action on abnormal situations in accordance with procedures

4.1

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

4.2

Describe impacts of any changes upstream and downstream

4.3

Recognise actual and developing situations which may require action

4.4

Apply operational knowledge to resolve problems

4.5

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

4.6

Follow through items initiated until final resolution has occurred

5

Isolate and de-isolate biochemical unit and its component plant items

5.1

Complete any required pre-start checks

5.2

Start up/shut down biochemical unit according to its type and duty in liaison with other personnel

5.3

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

5.4

Isolate entire biochemical unit and/or any component plant item

5.5

Make safe for required work

5.6

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

5.7

De-isolate and prepare biochemical unit/plant item for return to service

6

Clean reactors/vessels

6.1

Identify cleaning requirements

6.2

Clean to requirements according to procedures

6.3

Retain microorganisms contained in the plant and prepare for reuse as appropriate

6.4

Dispose of waste materials according to procedures

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

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, 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 are predictable and have known solutions and include one or more of the following:

sudden changes in feed (rate, composition, concentration)

changes in required production rate

changes in ambient conditions (e.g. summer to winter operation)

handling a plant shutdown without allowing the microorganisms to die

control of degree of agitation

settling/removal/recycling of microorganisms

feed variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem

Non-routine problems

Non-routine problems are unexpected problems, or variations of previous problems and 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

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

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 both 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

Bioreactor system

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

pumps (feed and dosing pumps)

utilities and services, such as air

agitators

air/gas supply and/or removal

temperature control equipment, such as heaters, coolers and heat exchangers

other equipment integral to the operation of the bioreactor system

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 biochemical unit 
Note any outstanding/incomplete work 
Check operational status of biochemical unit 
Describe the type of biochemical plant unit, the component plant items and their duties 
Complete routine checks, logs and paperwork 
Check performance of all ancillaries (such as mixing and heat exchange) 
Recognise and interpret trends in bioreactor data/appearance 
Recognise the signs of potential and actual problems 
Identify the consequences to the bioreactor processes of the identified changes, trends and problems 
Keep conditions within the optimum range 
Take action to minimise the impact on health, safety and environment (HSE) and the business of potential and actual problems 
Predict from rates and schedule when a change will be required 
Give advanced notice of change to work team 
Prepare plant for the change 
Predict the required amount of adjustment to cause the required change 
Make the change in a controlled manner without excessive variation 
Monitor the progress of the change and make minor adjustments as required 
Monitor biochemical unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses. 
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 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 biochemical 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 biochemical unit and/or any component plant item 
Make safe for required work 
Check biochemical unit/plant item is ready to be returned to service 
De-isolate and prepare biochemical unit/plant item for return to service 
Identify cleaning requirements 
Clean to requirements according to procedures 
Retain microorganisms contained in the plant and prepare for reuse as appropriate 
Dispose of waste materials according to procedures 

Forms

Assessment Cover Sheet

PMAOPS390 - Operate a biochemical process
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

PMAOPS390 - Operate a biochemical process

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: