In a typical scenario an operator uses a baffled mixing tank (or other mixer) to make a product to specification. This covers the loading of liquid and perhaps solid materials into the mixing equipment. In this example the operator monitors the mixing to ensure the components are dispersed appropriately and checks the resulting product to ensure it complies.

This unit does not cover mixing which is part of the preparation of materials (see PMAOPS105C Select and prepare materials) nor the incidental mixing which occurs in a reaction vessel (see PMAOPS220B Monitor chemical reactions in the process or PMAOPS302B Operate reactors and reactor systems) or in-line mixers (see PMAOPS201B Operate fluid flow equipment).3

The operator would:

identify and report operational problems

be aware of and contribute to a safe working environment

contribute to the safe and productive operation of the equipment

operate, monitor and maintain equipment using relevant procedures.

Generally the operator would be part of a team during start up and shut down procedures and would be expected to be capable of demonstrating competence in all parts of this unit. At all times they would be liaising and cooperating with other members of the team.

ELEMENT

PERFORMANCE CRITERIA

1. Prepare for work.

1.1. Identify work requirements

1.2. Identify and control hazards

1.3. Coordinate with appropriate personnel

2. Prepare mixing equipment.

2.1. Identify type of fluid mixer

2.2. Identify appropriate applications for the mixer type

2.3. Check materials.

3. Operate fluid mixing equipment.

3.1. Charge materials

3.2. Start up/shut down fluid mixing equipment as required

3.3. Adjust mixing conditions as required

3.4. Check product

3.5. Adjust product as instructed or to procedure

3.6. Discharge product

3.7. Complete routine checks and reports, taking action on unexpected readings and trends.

4. Isolate and de-isolate plant.

4.1. Isolate plant

4.2. Make safe for required work

4.3. Check plant is ready to be returned to service

4.4. Prepare plant for return to service.

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

Required skills

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving.

Required knowledge

Understanding of fluid mixing equipment and its integral equipment to a level needed to recognise and resolve operational problems. In particular it includes a knowledge of:

all items on a schematic of the mixing system and the function of each

fluid mixing principles, such as shear, viscosity and concepts of uniformity

principles of operation of fluid mixing equipment

physics of operation

correct methods of starting, stopping, operating and controlling mixing equipment

typical mixing problems, and their causes and remedy, within operator's scope of skill level and responsibility

duty of care

materials safety data sheets (MSDSs)

HAZCHEM symbols and codes

hazardous substances regulations

spill containment and disposal procedures

procedures related to this competency

environmental requirements related to waste disposal

workplace hazards and methods of controlling hazards.

hierarchy of control

communication protocols, eg radio, phone, computer, paper, permissions/authorities

routine problems, faults and their resolution

relevant alarms and actions

plant process idiosyncrasies

corrective action appropriate to the problem cause

function and troubleshooting of major components and their problems (such as impellors, seals or bearings)

types and causes of mixing problems within operator's scope of skill level and responsibility.

The Evidence Guide provides advice on assessment and must be read in conjunction with the Performance Criteria, Required Skills and Knowledge, the Range Statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Assessment of this unit should include demonstrated competence on actual plant and equipment in a work environment. The unit will be assessed in as holistic a manner as is practical and may be integrated with the assessment of other relevant units of competency. Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation may be required to allow for assessment of parts of this unit. Simulation should be based on the actual plant and will include walk-throughs of the relevant competency components. Simulations may also include the use of case studies/scenarios and role plays.

This unit of competency requires a significant body of knowledge which will be assessed through questioning and the use of what-if scenarios both on the plant (during demonstration of normal operations and walk-throughs of abnormal operations) and off the plant.

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action. The emphasis should be on the ability to stay out of trouble rather than on recovery from a disaster.

Consistent performance should be demonstrated. In particular look to see that:

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

the range of possible causes can be identified and analysed and the most likely cause determined

appropriate action is taken to ensure a timely return to full performance

obvious problems in related plant areas are recognised and an appropriate contribution made to their solution.

These aspects may be best assessed using a range of scenarios/case studies/what-ifs as the stimulus with a walk-through forming part of the response. These assessment activities should include a range of problems, including new, unusual and improbable situations which may have been generated from the past incident history of the plant, incidents on similar plants around the world, hazard analysis activities and similar sources.

Context of and specific resources for assessment

Assessment will require access to an operating plant over an extended period of time, or a suitable method of gathering evidence of operating ability over a range of situations. A bank of scenarios/case studies/what-ifs will be required as will a bank of questions which will be used to probe the reasoning behind the observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with units about:

measurements

housekeeping

communication.

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

MSAPMOHS200A Work safely.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the communication ability, language and literacy capacity of the assessee and the work being performed.

The Range Statement relates to the unit of competency as a whole. It allows for different work environments and situations that may affect performance. Bold italicised wording, if used in the Performance Criteria, is detailed below. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs if the candidate, accessibility of the item, and local industry and regional contexts.

Codes of practice/ standards

Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.

Context

Fluid mixing processes can vary from continuous mixing processes as typically found in oil plants to batch mixing as commonly used in chemical plants and paint manufacture. It covers the mixing of two or more materials to make a product.

Equipment

This competency includes items of equipment such as:

mixers for low, medium and high viscosity fluids

jet mixing

top and side entry mixers

propeller, and pitched and square bladed turbine impellers.

Problems

Typical problems include incorrect:

mixing time

power consumption

uniformity

vortexing

aeration.

Remedial actions

Remedial actions include changing:

position and angle of baffles where appropriate

impellor (angle, size, shape or speed)

feed rate of fluids.

Mixing conditions

Mixing conditions may be adjusted by:

baffles

mixer speed

mixing duration

other means

Start up shut down as required

Start up shut down as required includes:

start up and shut down to/from normal operating conditions

start up and shut down to/from isolated, cold, empty

all other conditions experienced on the plant.

ie from any condition to any condition experienced on the plant.

Appropriate action

Appropriate action includes:

determining problems needing action

determining possible fault causes

rectifying problem using appropriate solution within area of responsibility

following through items initiated until final resolution has occurred

reporting problems outside area of responsibility to designated person.

Procedures

Procedures may be written, verbal, computer-based or in some other form. They include:

all work instructions

standard operating procedures

formulas/recipes

batch sheets

temporary instructions

any similar instructions provided for the smooth running of the plant.

For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.

Health, safety and environment (HSE)

All operations to which this unit applies are subject to stringent health, safety and environment requirements, which may be imposed through State or Federal legislation, and these must not be compromised at any time. Where there is an apparent conflict between Performance Criteria and HSE requirements, the HSE requirements take precedence.

Unit sector

Operational/technical

This unit contains employability skills.