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

PMAOPS405 Mapping and Delivery Guide
Operate complex control systems

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMAOPS405 - Operate complex control systems
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to operate a complex control panel. The panel will control entire plant areas and multiple products/process streams and will use a large number of control loops and a broad range of control algorithms; and will probably include advanced process control (APC) as one of its operations. Its operation will require managing multiple complex tasks. This unit of competency includes all such items of equipment and unit operations which form part of the control system, including as appropriate to the facility: process control systems (e.g. distributed control systems (DCS), and supervisory control and data acquisition (SCADA)) use of multiple control systemsinteracting control loops/cascade controlpersonal computersprintersfire and gas detection/protection systemsemergency shutdown (ESD) systemscommunications systems.This unit of competency applies to senior technicians or those in similar roles who are required to apply in-depth knowledge of process and plant to in order to operate, monitor and optimise an entire plant area consisting of several plant units/systems, solve process problems and liaise with other plant areas. This control system would typically be an advanced control system and may include operation of simpler control systems as part of its operation. The panel will typically be located off plant in a control room.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 complex control system, controlling a real or simulated process requiring demonstration of operation and responding to problems

may use industry-based simulation for all 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: Use operator interface
  • Use keyboards, track ball and monitor and/or stand-alone controllers to access control system/panel
  • Monitor the process using the operator interfaces
  • Select appropriate controller modes
  • Access historical data and information
  • Acknowledge messages and alarms
  • Access advanced control features as appropriate
       
Element: Access control information
  • Obtain relevant data and information from the control system by applying systems knowledge
  • Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults
  • Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics
  • Determine the overall operating effectiveness of the plant area related to the required targets for the area
  • Record process variations/irregularities to procedures
       
Element: Control process variations and monitor operations
  • Monitor process using all information available in the control room
  • Use historical data to assist the identification of problems
  • Process available information to identify potential faults
  • Undertake required set point/output changes to meet plant area and process requirements
  • Adjust production in response to test results and control panel information
  • Monitor key process and environmental variables and take action to achieve required outcomes
  • Adjust controller settings in accordance with procedures
  • Use advanced control features as appropriate
  • Turn controller features on and off to meet process and control needs
  • Optimise operation of entire plant area in accordance with guidelines
  • Undertake calibration operations in accordance with procedures.
  • Coordinate with stakeholders external to the plant area in accordance with procedures
  • Record adjustments and variations to specifications/schedules
  • Communicate to appropriate personnel as required
       
Element: Facilitate planned and unplanned process start-ups and shutdowns
  • Select and apply procedures to planned start-up and shutdown processes.
  • Select and apply procedures to unplanned shutdown processes
  • Implement all required emergency responses
  • Communicate necessary information to all personnel affected by events
  • Log all required information
       
Element: Respond to alarms or out-of-specification conditions
  • Identify system(s) affected by the alarm or condition
  • Interpret alarms and prioritise actions to be taken
  • Respond to the alarm or incident by following procedures
  • Deal with any out-of-specification material in accordance with procedures
  • Communicate the problem/solution to appropriate personnel
  • Record the information as required
  • Provide details of the alarm and action taken to the next shift at changeover
  • Follow up on the incident to see that appropriate action has been taken
       
Element: Control hazards
  • Identify hazards/changes in hazards in the production/processing work area
  • Assess the risks arising from those hazards
  • Implement measures to control risks in line with procedures and duty of care
  • Communicate hazards and hazard controls to affected personnel
       
Element: Resolve other problems within scope of responsibility
  • Identify possible problems in equipment, control systems or process
  • Determine problems needing action
  • Determine possible fault causes
  • Rectify problem using appropriate solution within area of responsibility
  • Follow initiated items through until final resolution has occurred
  • Report problems outside area of responsibility to designated person
       


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

Use operator interface

1.1

Use keyboards, track ball and monitor and/or stand-alone controllers to access control system/panel

1.2

Monitor the process using the operator interfaces

1.3

Select appropriate controller modes

1.4

Access historical data and information

1.5

Acknowledge messages and alarms

1.6

Access advanced control features as appropriate

2

Access control information

2.1

Obtain relevant data and information from the control system by applying systems knowledge

2.2

Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults

2.3

Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics

2.4

Determine the overall operating effectiveness of the plant area related to the required targets for the area

2.5

Record process variations/irregularities to procedures

3

Control process variations and monitor operations

3.1

Monitor process using all information available in the control room

3.2

Use historical data to assist the identification of problems

3.3

Process available information to identify potential faults

3.4

Undertake required set point/output changes to meet plant area and process requirements

3.5

Adjust production in response to test results and control panel information

3.6

Monitor key process and environmental variables and take action to achieve required outcomes

3.7

Adjust controller settings in accordance with procedures

3.8

Use advanced control features as appropriate

3.9

Turn controller features on and off to meet process and control needs

3.10

Optimise operation of entire plant area in accordance with guidelines

3.11

Undertake calibration operations in accordance with procedures.

3.12

Coordinate with stakeholders external to the plant area in accordance with procedures

3.13

Record adjustments and variations to specifications/schedules

3.14

Communicate to appropriate personnel as required

4

Facilitate planned and unplanned process start-ups and shutdowns

4.1

Select and apply procedures to planned start-up and shutdown processes.

4.2

Select and apply procedures to unplanned shutdown processes

4.3

Implement all required emergency responses

4.4

Communicate necessary information to all personnel affected by events

4.5

Log all required information

5

Respond to alarms or out-of-specification conditions

5.1

Identify system(s) affected by the alarm or condition

5.2

Interpret alarms and prioritise actions to be taken

5.3

Respond to the alarm or incident by following procedures

5.4

Deal with any out-of-specification material in accordance with procedures

5.5

Communicate the problem/solution to appropriate personnel

5.6

Record the information as required

5.7

Provide details of the alarm and action taken to the next shift at changeover

5.8

Follow up on the incident to see that appropriate action has been taken

6

Control hazards

6.1

Identify hazards/changes in hazards in the production/processing work area

6.2

Assess the risks arising from those hazards

6.3

Implement measures to control risks in line with procedures and duty of care

6.4

Communicate hazards and hazard controls to affected personnel

7

Resolve other problems within scope of responsibility

7.1

Identify possible problems in equipment, control systems or process

7.2

Determine problems needing action

7.3

Determine possible fault causes

7.4

Rectify problem using appropriate solution within area of responsibility

7.5

Follow initiated items through until final resolution has occurred

7.6

Report problems outside area of responsibility to designated person

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:

interpret and respond to panel messages and alarms

obtain and interpret data from the control system to minimise variation and maximise performance

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

select and apply procedures for planned and unplanned start-up/shutdown

identify hazards and risks and apply risk control procedures

communicate and negotiate effectively with all stakeholders

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

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

process control system malfunction

power/utility failures

software problems

multitasking.

Evidence must be provided that demonstrates knowledge of:

advanced control features

interactions between control loops

interactions between plant units within the entire plant

the architecture and location of the process/production equipment

specific plant process operations

interactions between plant items/processes

product specifications and tolerances, systems operating parameters and system integrity limits

process control philosophies and strategies

emergency shutdown (ESD) procedures

relevant science of the process (e.g. physics, chemistry and biochemistry) to the level of identifying and manipulating factors controlling process rate and product properties, and identifying and resolving potential problems

basic science of upstream and downstream processes

interactions between plant area and other value stream members

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

complex process drawings (e.g. piping and instrumentation diagram (P&ID), process flow diagram (PFD), and cause and effect

basis of control for the plant

instrumentation and control systems, including feed forward, feed-back and open control

instrumentation and control system components (e.g. relevant primary sensing devices, final control elements and transducers/transmitters)

control loops (including proportional integral derivative (PID) control, set points, controlled variable and indicated variable)

interaction between multiple control loops (including cascade control)

impacts of changing controller settings and the limits within which changes can be made

effective communication techniques

organisation procedures

uninterrupt power supply (UPS) and its applications and use

duty of care obligations

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

Use operator interface

1.1

Use keyboards, track ball and monitor and/or stand-alone controllers to access control system/panel

1.2

Monitor the process using the operator interfaces

1.3

Select appropriate controller modes

1.4

Access historical data and information

1.5

Acknowledge messages and alarms

1.6

Access advanced control features as appropriate

2

Access control information

2.1

Obtain relevant data and information from the control system by applying systems knowledge

2.2

Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults

2.3

Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics

2.4

Determine the overall operating effectiveness of the plant area related to the required targets for the area

2.5

Record process variations/irregularities to procedures

3

Control process variations and monitor operations

3.1

Monitor process using all information available in the control room

3.2

Use historical data to assist the identification of problems

3.3

Process available information to identify potential faults

3.4

Undertake required set point/output changes to meet plant area and process requirements

3.5

Adjust production in response to test results and control panel information

3.6

Monitor key process and environmental variables and take action to achieve required outcomes

3.7

Adjust controller settings in accordance with procedures

3.8

Use advanced control features as appropriate

3.9

Turn controller features on and off to meet process and control needs

3.10

Optimise operation of entire plant area in accordance with guidelines

3.11

Undertake calibration operations in accordance with procedures.

3.12

Coordinate with stakeholders external to the plant area in accordance with procedures

3.13

Record adjustments and variations to specifications/schedules

3.14

Communicate to appropriate personnel as required

4

Facilitate planned and unplanned process start-ups and shutdowns

4.1

Select and apply procedures to planned start-up and shutdown processes.

4.2

Select and apply procedures to unplanned shutdown processes

4.3

Implement all required emergency responses

4.4

Communicate necessary information to all personnel affected by events

4.5

Log all required information

5

Respond to alarms or out-of-specification conditions

5.1

Identify system(s) affected by the alarm or condition

5.2

Interpret alarms and prioritise actions to be taken

5.3

Respond to the alarm or incident by following procedures

5.4

Deal with any out-of-specification material in accordance with procedures

5.5

Communicate the problem/solution to appropriate personnel

5.6

Record the information as required

5.7

Provide details of the alarm and action taken to the next shift at changeover

5.8

Follow up on the incident to see that appropriate action has been taken

6

Control hazards

6.1

Identify hazards/changes in hazards in the production/processing work area

6.2

Assess the risks arising from those hazards

6.3

Implement measures to control risks in line with procedures and duty of care

6.4

Communicate hazards and hazard controls to affected personnel

7

Resolve other problems within scope of responsibility

7.1

Identify possible problems in equipment, control systems or process

7.2

Determine problems needing action

7.3

Determine possible fault causes

7.4

Rectify problem using appropriate solution within area of responsibility

7.5

Follow initiated items through until final resolution has occurred

7.6

Report problems outside area of responsibility to designated person

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

gases and liquids under pressure

equipment failures

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

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

Routine problems

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

operating without advanced control features

loss of power/utilities

analysing failure modes

variation/loss of feed

unstable control of pressure, temperature level and flows

control equipment failure

process plant trips

change in atmospheric conditions (rain, temperature, wind and lightning)

emergency situations

control function problems

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

Alarms or abnormal conditions

Alarms or other abnormal conditions include the following:

emergency, including emergency shutdown (ESD)

partial or complete controller failure

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
Use keyboards, track ball and monitor and/or stand-alone controllers to access control system/panel 
Monitor the process using the operator interfaces 
Select appropriate controller modes 
Access historical data and information 
Acknowledge messages and alarms 
Access advanced control features as appropriate 
Obtain relevant data and information from the control system by applying systems knowledge 
Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults 
Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics 
Determine the overall operating effectiveness of the plant area related to the required targets for the area 
Record process variations/irregularities to procedures 
Monitor process using all information available in the control room 
Use historical data to assist the identification of problems 
Process available information to identify potential faults 
Undertake required set point/output changes to meet plant area and process requirements 
Adjust production in response to test results and control panel information 
Monitor key process and environmental variables and take action to achieve required outcomes 
Adjust controller settings in accordance with procedures 
Use advanced control features as appropriate 
Turn controller features on and off to meet process and control needs 
Optimise operation of entire plant area in accordance with guidelines 
Undertake calibration operations in accordance with procedures. 
Coordinate with stakeholders external to the plant area in accordance with procedures 
Record adjustments and variations to specifications/schedules 
Communicate to appropriate personnel as required 
Select and apply procedures to planned start-up and shutdown processes. 
Select and apply procedures to unplanned shutdown processes 
Implement all required emergency responses 
Communicate necessary information to all personnel affected by events 
Log all required information 
Identify system(s) affected by the alarm or condition 
Interpret alarms and prioritise actions to be taken 
Respond to the alarm or incident by following procedures 
Deal with any out-of-specification material in accordance with procedures 
Communicate the problem/solution to appropriate personnel 
Record the information as required 
Provide details of the alarm and action taken to the next shift at changeover 
Follow up on the incident to see that appropriate action has been taken 
Identify hazards/changes in hazards in the production/processing work area 
Assess the risks arising from those hazards 
Implement measures to control risks in line with procedures and duty of care 
Communicate hazards and hazard controls to affected personnel 
Identify possible problems in equipment, control systems or process 
Determine problems needing action 
Determine possible fault causes 
Rectify problem using appropriate solution within area of responsibility 
Follow initiated items through until final resolution has occurred 
Report problems outside area of responsibility to designated person 

Forms

Assessment Cover Sheet

PMAOPS405 - Operate complex control systems
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

PMAOPS405 - Operate complex control systems

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: