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

PMAOPS522 Mapping and Delivery Guide
Coordinate plant shutdown

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMAOPS522 - Coordinate plant shutdown
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to coordinate a planned, major shutdown. A planned, major shutdown may be for whole plant/system, one plant area or one plant in an integrated complex and will typically occur to enable:regulatory vessel inspection (PVI)major maintenanceupgrades or refitscatalyst and/or column repackingother activities which are scheduled for the shutdown.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 operations and problem solving in order to coordinate shutdown sequence to ensure all process shutdown activities completed to schedule, coordinate the activities of a number of work groups, analyse/problem solve and develop contingency plans, and identify and coordinate resources and pre-shutdown requirements. This unit of competency applies to a plant technician who is performing the plant shutdown coordinator role as their primary activity. This technician would be part of a team working with technical experts, maintenance experts, contractor representatives, process/production teams and management. 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 is best done from a report and/or folio of evidence drawn from:

a single project which provides sufficient evidence of the requirements of all the elements and performance criteria

multiple smaller projects which together provide sufficient evidence of the requirements of all the elements and performance criteria.

A third-party report, or similar, may be needed to testify to the work done by the individual, particularly when the project has been done as part of a project team.

Assessment should use a real project in an operational workplace. Where this is not possible or practical, assessment must occur using 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.

Knowledge evidence may be collected concurrently with performance evidence 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: Identify shutdown work scope
  • Analyse relevant information for activities intended for the shutdown
  • Determine all activities intended for shutdown
  • Confirm priorities and identify all essential work
  • Resolve conflicts between proposed activities
       
Element: Plan and schedule resources
  • Identify each individual task in the shutdown process
  • Determine resources required for each task and assign appropriate owner
  • Determine prerequisite tasks prior to shutting down process
  • Ensure hazards are identified and controls are in place
  • Ensure all safety and testing equipment is calibrated and on site prior to shutdown commencing
  • Compile a schedule to track shutdown and equipment preparation sequence
       
Element: Coordinate plant/ equipment shutdown sequence
  • Prepare/review shutdown documentation
  • Coordinate plant shutdown according to procedures
  • Track plant shutdown progress
  • Coordinate execution of critical function test during shutdown phase
  • Coordinate equipment preparation
  • Validate equipment is safe to hand over to appropriate work party
       
Element: Hand over plant/ equipment to relevant work party
  • Hand over plant and equipment to relevant work group according to site protocol
  • Perform safety audits during shutdown work
  • Record/report health, safety and environment (HSE) non-conformance
  • Communicate as and when required
  • Monitor shutdown work against critical path
  • Monitor resource usage and take action
  • Identify barriers to achieving shutdown critical path and negotiate solution
       
Element: Communicate with all relevant stakeholders
  • Communicate shutdown plan/schedule to operations team
  • Attend and contribute to regular shutdown progress meetings
  • Record and report daily shutdown activities
  • Ensure all authorisations required for tasks have been obtained
  • Identify, communicate and mange HSE issues arising during execution of shutdown activities
  • Contribute to post shutdown review
       
Element: Return plant to service
  • Confirm that all scheduled work on equipment is complete before hand back is accepted
  • Ensure equipment hand back documentation complete according to site protocol
  • Coordinate pre-start equipment integrity checks
  • Coordinate and validate plant de-isolation and preparation for service
  • Ensure appropriate plant start-up authority is obtained
  • Coordinate start-up critical function tests as required
  • Coordinate and record plant start-up progress
       


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

Identify shutdown work scope

1.1

Analyse relevant information for activities intended for the shutdown

1.2

Determine all activities intended for shutdown

1.3

Confirm priorities and identify all essential work

1.4

Resolve conflicts between proposed activities

2

Plan and schedule resources

2.1

Identify each individual task in the shutdown process

2.2

Determine resources required for each task and assign appropriate owner

2.3

Determine prerequisite tasks prior to shutting down process

2.4

Ensure hazards are identified and controls are in place

2.5

Ensure all safety and testing equipment is calibrated and on site prior to shutdown commencing

2.6

Compile a schedule to track shutdown and equipment preparation sequence

3

Coordinate plant/ equipment shutdown sequence

3.1

Prepare/review shutdown documentation

3.2

Coordinate plant shutdown according to procedures

3.3

Track plant shutdown progress

3.4

Coordinate execution of critical function test during shutdown phase

3.5

Coordinate equipment preparation

3.6

Validate equipment is safe to hand over to appropriate work party

4

Hand over plant/ equipment to relevant work party

4.1

Hand over plant and equipment to relevant work group according to site protocol

4.2

Perform safety audits during shutdown work

4.3

Record/report health, safety and environment (HSE) non-conformance

4.4

Communicate as and when required

4.5

Monitor shutdown work against critical path

4.6

Monitor resource usage and take action

4.7

Identify barriers to achieving shutdown critical path and negotiate solution

5

Communicate with all relevant stakeholders

5.1

Communicate shutdown plan/schedule to operations team

5.2

Attend and contribute to regular shutdown progress meetings

5.3

Record and report daily shutdown activities

5.4

Ensure all authorisations required for tasks have been obtained

5.5

Identify, communicate and mange HSE issues arising during execution of shutdown activities

5.6

Contribute to post shutdown review

6

Return plant to service

6.1

Confirm that all scheduled work on equipment is complete before hand back is accepted

6.2

Ensure equipment hand back documentation complete according to site protocol

6.3

Coordinate pre-start equipment integrity checks

6.4

Coordinate and validate plant de-isolation and preparation for service

6.5

Ensure appropriate plant start-up authority is obtained

6.6

Coordinate start-up critical function tests as required

6.7

Coordinate and record plant start-up progress

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:

lead and coordinate shutdown team to ensure safe and efficient plant shutdown and preparation according to procedures without incident

record and report all aspects of shutdown activities to stakeholders according to enterprise protocol

communicate and negotiate effectively with technical (process) experts, maintenance experts, contractor representatives, production management and other stakeholders to obtain the best outcome for the shutdown from competing priorities

determine resource requirements, including:

utility services, such as steam, nitrogen, power, water and chemicals

workforce, such as operators, maintenance, contractors, engineers, laboratory staff, safety observer and standby rescue crew

mobile equipment, such as elevated work platforms, Hiab, vacuum trucks and drip trays

other equipment, such as hoses, plugs and caps, scaffold and extra fire protection equipment.

Evidence must be provided that demonstrates knowledge of:

interpretation of project planning tools being used

a comprehensive knowledge of plant shutdown events and their impact on upstream and downstream interfaces

plant/equipment/processes impacted by the shutdown

safe working practices related to the type of plant and equipment being shut down and worked on

correct methods of shutting down plant items

organisation procedures.

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

Identify shutdown work scope

1.1

Analyse relevant information for activities intended for the shutdown

1.2

Determine all activities intended for shutdown

1.3

Confirm priorities and identify all essential work

1.4

Resolve conflicts between proposed activities

2

Plan and schedule resources

2.1

Identify each individual task in the shutdown process

2.2

Determine resources required for each task and assign appropriate owner

2.3

Determine prerequisite tasks prior to shutting down process

2.4

Ensure hazards are identified and controls are in place

2.5

Ensure all safety and testing equipment is calibrated and on site prior to shutdown commencing

2.6

Compile a schedule to track shutdown and equipment preparation sequence

3

Coordinate plant/ equipment shutdown sequence

3.1

Prepare/review shutdown documentation

3.2

Coordinate plant shutdown according to procedures

3.3

Track plant shutdown progress

3.4

Coordinate execution of critical function test during shutdown phase

3.5

Coordinate equipment preparation

3.6

Validate equipment is safe to hand over to appropriate work party

4

Hand over plant/ equipment to relevant work party

4.1

Hand over plant and equipment to relevant work group according to site protocol

4.2

Perform safety audits during shutdown work

4.3

Record/report health, safety and environment (HSE) non-conformance

4.4

Communicate as and when required

4.5

Monitor shutdown work against critical path

4.6

Monitor resource usage and take action

4.7

Identify barriers to achieving shutdown critical path and negotiate solution

5

Communicate with all relevant stakeholders

5.1

Communicate shutdown plan/schedule to operations team

5.2

Attend and contribute to regular shutdown progress meetings

5.3

Record and report daily shutdown activities

5.4

Ensure all authorisations required for tasks have been obtained

5.5

Identify, communicate and mange HSE issues arising during execution of shutdown activities

5.6

Contribute to post shutdown review

6

Return plant to service

6.1

Confirm that all scheduled work on equipment is complete before hand back is accepted

6.2

Ensure equipment hand back documentation complete according to site protocol

6.3

Coordinate pre-start equipment integrity checks

6.4

Coordinate and validate plant de-isolation and preparation for service

6.5

Ensure appropriate plant start-up authority is obtained

6.6

Coordinate start-up critical function tests as required

6.7

Coordinate and record plant start-up progress

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.

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

Scheduling

Scheduling may be electronic or paper-based and include at least one more of the following:

electronic databases, such as Access, DB, and Oracle

project management software (e.g. Project, Gantt charts, critical path method (CPM) and programmed evaluation and review technique (PERT))

other electronic forms, such as spreadsheets

card files

other paper-based systems

other specialised planning software

paper techniques

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
Analyse relevant information for activities intended for the shutdown 
Determine all activities intended for shutdown 
Confirm priorities and identify all essential work 
Resolve conflicts between proposed activities 
Identify each individual task in the shutdown process 
Determine resources required for each task and assign appropriate owner 
Determine prerequisite tasks prior to shutting down process 
Ensure hazards are identified and controls are in place 
Ensure all safety and testing equipment is calibrated and on site prior to shutdown commencing 
Compile a schedule to track shutdown and equipment preparation sequence 
Prepare/review shutdown documentation 
Coordinate plant shutdown according to procedures 
Track plant shutdown progress 
Coordinate execution of critical function test during shutdown phase 
Coordinate equipment preparation 
Validate equipment is safe to hand over to appropriate work party 
Hand over plant and equipment to relevant work group according to site protocol 
Perform safety audits during shutdown work 
Record/report health, safety and environment (HSE) non-conformance 
Communicate as and when required 
Monitor shutdown work against critical path 
Monitor resource usage and take action 
Identify barriers to achieving shutdown critical path and negotiate solution 
Communicate shutdown plan/schedule to operations team 
Attend and contribute to regular shutdown progress meetings 
Record and report daily shutdown activities 
Ensure all authorisations required for tasks have been obtained 
Identify, communicate and mange HSE issues arising during execution of shutdown activities 
Contribute to post shutdown review 
Confirm that all scheduled work on equipment is complete before hand back is accepted 
Ensure equipment hand back documentation complete according to site protocol 
Coordinate pre-start equipment integrity checks 
Coordinate and validate plant de-isolation and preparation for service 
Ensure appropriate plant start-up authority is obtained 
Coordinate start-up critical function tests as required 
Coordinate and record plant start-up progress 

Forms

Assessment Cover Sheet

PMAOPS522 - Coordinate plant shutdown
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

PMAOPS522 - Coordinate plant shutdown

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: