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

PMASUP440 Mapping and Delivery Guide
Commission/recommission plant

Version 1.0
Issue Date: May 2024


Qualification -
Unit of Competency PMASUP440 - Commission/recommission plant
Description
Employability Skills
Learning Outcomes and Application This unit of competency covers the skills and knowledge required to commission new plant/pipeline or recommission significantly modified plant/pipeline. It applies to plant/pipeline, such as on or offshore plant, wellheads, transmission pipelines or similar.Commissioning refers to the start-up of a new plant or plant unit and the associated equipment for the first time. Recommissioning refers to the start-up of an existing plant following major modifications, rebuild or reconfiguration.This unit of competency applies to senior technicians and those in similar roles who are required to apply in-depth knowledge of process and plant in order to ensure design of new/modified plant meets safety and operability requirements, plan and coordinate commissioning/recommissioning, and complete required documentation. The technician would not normally have a 'hands on' operating role for all items of equipment, but may have a 'hands on' role for major items of equipment; however this is not required as part of this competency. 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 Support
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: Contribute to/review the design of plant/ equipment
  • Apply process understanding to the design process
  • Identify the role and purpose of the plant and equipment
  • Ensure design meets the identified need
  • Identify process conditions and apply to hazard and operability studies (HAZOP)
  • Undertake investigations following hazard studies
  • Record and report findings
       
Element: Take part in commissioning planning
  • Ensure the work is coordinated effectively with others involved on the work site
  • Obtain materials necessary to complete the work and check against job requirements
  • Obtain tools and equipment necessary to carry out the work and check for correct operation and safety
  • Prepare plans to ensure that procedures are performed in the correct sequence
  • Obtain approvals, where necessary, from appropriate authorities
       
Element: Participate in acceptance of plant/ equipment
  • Undertake pre-commissioning activities
  • Complete safety acceptance documentation
  • Identify, record and report problems or non-conformance
  • Conduct trials/test runs
  • Record and report performance data
       
Element: Commission system
  • Bring the plant/plant systems/pipeline online
  • Make and report adjustments
  • Prepare reports in accordance with legislative and company requirements to maintain the historical record
       
Element: Evaluate results and identify modifications
  • Identify modifications and improvements required
  • Check specifications, procedures and training material match the final system/procedures
  • Complete documentation and report to appropriate personnel
       


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

Contribute to/review the design of plant/ equipment

1.1

Apply process understanding to the design process

1.2

Identify the role and purpose of the plant and equipment

1.3

Ensure design meets the identified need

1.4

Identify process conditions and apply to hazard and operability studies (HAZOP)

1.5

Undertake investigations following hazard studies

1.6

Record and report findings

2

Take part in commissioning planning

2.1

Ensure the work is coordinated effectively with others involved on the work site

2.2

Obtain materials necessary to complete the work and check against job requirements

2.3

Obtain tools and equipment necessary to carry out the work and check for correct operation and safety

2.4

Prepare plans to ensure that procedures are performed in the correct sequence

2.5

Obtain approvals, where necessary, from appropriate authorities

3

Participate in acceptance of plant/ equipment

3.1

Undertake pre-commissioning activities

3.2

Complete safety acceptance documentation

3.3

Identify, record and report problems or non-conformance

3.4

Conduct trials/test runs

3.5

Record and report performance data

4

Commission system

4.1

Bring the plant/plant systems/pipeline online

4.2

Make and report adjustments

4.3

Prepare reports in accordance with legislative and company requirements to maintain the historical record

5

Evaluate results and identify modifications

5.1

Identify modifications and improvements required

5.2

Check specifications, procedures and training material match the final system/procedures

5.3

Complete documentation and report to appropriate personnel

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:

plan, coordinate and monitor pre-commissioning, commissioning/recommissioning activities

arrange resources as required

communicate effectively with stakeholders, including manufacturers, engineering personnel, designers, contractors and maintenance and other company personnel

participate in and/or review hazard and operability studies (HAZOP), hazard analysis studies (HAZAN) or similar techniques

participate in and/or review design or modification plans

identify hazards and risks and apply risk control procedures

complete written/electronic documentation.

Evidence must be provided that demonstrates knowledge of:

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

principles of operation of items of equipment in the system

principles of operation of instrumentation

principles of basic control systems

process control philosophies and strategies

interactions between plant items/processes

systems’ operating parameters

system integrity limits

product tolerances, limitations and specifications

types and purpose of typical pre-commissioning activities, including:

checking plant is built to design

ensuring plant is safe to operate

ensuring plant area and plant internals are clean and clear of debris

functional checking of equipment and ancillaries

types and purpose of typical commissioning/recommissioning activities, including:

trial running of equipment

use of trial materials in plant

safe introduction of process materials to plant

producing product within specification

bringing plant to design rates

solving operational problems

disposal of waste generated in the start-up

science (e.g. physics, chemistry and biochemistry) relevant to process and materials

process parameters and limits (e.g. temperature, pressure, flow and pH)

correct methods of starting, stopping, operating and controlling plant

routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions.

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

Contribute to/review the design of plant/ equipment

1.1

Apply process understanding to the design process

1.2

Identify the role and purpose of the plant and equipment

1.3

Ensure design meets the identified need

1.4

Identify process conditions and apply to hazard and operability studies (HAZOP)

1.5

Undertake investigations following hazard studies

1.6

Record and report findings

2

Take part in commissioning planning

2.1

Ensure the work is coordinated effectively with others involved on the work site

2.2

Obtain materials necessary to complete the work and check against job requirements

2.3

Obtain tools and equipment necessary to carry out the work and check for correct operation and safety

2.4

Prepare plans to ensure that procedures are performed in the correct sequence

2.5

Obtain approvals, where necessary, from appropriate authorities

3

Participate in acceptance of plant/ equipment

3.1

Undertake pre-commissioning activities

3.2

Complete safety acceptance documentation

3.3

Identify, record and report problems or non-conformance

3.4

Conduct trials/test runs

3.5

Record and report performance data

4

Commission system

4.1

Bring the plant/plant systems/pipeline online

4.2

Make and report adjustments

4.3

Prepare reports in accordance with legislative and company requirements to maintain the historical record

5

Evaluate results and identify modifications

5.1

Identify modifications and improvements required

5.2

Check specifications, procedures and training material match the final system/procedures

5.3

Complete documentation and report to appropriate personnel

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

gases and liquids under pressure

structural hazards

structural collapse

equipment failures

industrial (machinery, equipment and product)

equipment or product mass

noise, rotational equipment or vibration

plant services (steam, condensate and cooling water)

limited head spaces or overhangs

working at heights, in restricted or confined spaces, or in environments subjected to heat, noise, dusts or vapours

flammability and explosivity

hazardous products and materials

unauthorised personnel

sharp edges, protrusions or obstructions

slippery surfaces, spills or leaks

extreme weather

other hazards that might arise

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

Documentation

Documentation includes one or more of the following:

operating procedures

work health and safety (WHS) and environmental legislative requirements

manufacturer specifications

appropriate authority approvals (e.g. local councils, road authority, sewerage, stormwater, electricity, water and telephone)

quality assurance inspection and test reports

Plant/pipeline systems

This unit of competency includes all items of equipment and unit operations which form part of the pipeline system including, as relevant to a particular plant/pipeline:

pipes

valves

operating units

electrical and electronic components

programmable logic controllers (PLCs)/distributed control system (DCS) or other plant controls

cathodic protection (CP)

pressure/flow/temperature, regulation and meters

Tools, materials and equipment

Tools, materials and equipment include one or more of the following:

hand tools,

power operated tools

plant

emergency equipment

electrical and electronic test equipment

gas detectors

air compressor

water pump

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
Apply process understanding to the design process 
Identify the role and purpose of the plant and equipment 
Ensure design meets the identified need 
Identify process conditions and apply to hazard and operability studies (HAZOP) 
Undertake investigations following hazard studies 
Record and report findings 
Ensure the work is coordinated effectively with others involved on the work site 
Obtain materials necessary to complete the work and check against job requirements 
Obtain tools and equipment necessary to carry out the work and check for correct operation and safety 
Prepare plans to ensure that procedures are performed in the correct sequence 
Obtain approvals, where necessary, from appropriate authorities 
Undertake pre-commissioning activities 
Complete safety acceptance documentation 
Identify, record and report problems or non-conformance 
Conduct trials/test runs 
Record and report performance data 
Bring the plant/plant systems/pipeline online 
Make and report adjustments 
Prepare reports in accordance with legislative and company requirements to maintain the historical record 
Identify modifications and improvements required 
Check specifications, procedures and training material match the final system/procedures 
Complete documentation and report to appropriate personnel 

Forms

Assessment Cover Sheet

PMASUP440 - Commission/recommission plant
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

PMASUP440 - Commission/recommission plant

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: