Application
This unit of competency covers the skills and knowledge required to operate a local control panel.
These controllers use simple control algorithms and only a limited number of control loops. Typically it will be located on the plant, but may be located off-plant. This unit of competency also applies to simple panels in a control room which are not part of the main control panel.
This unit of competency applies to operators who are required to start up and shut down equipment using the local control system; monitor and control process variables, such as temperature or pressure; operate valves and pumps to add raw materials and/or additives; and discharge product.
The operator is expected to be capable of performing all parts of this unit of competency. Generally the operator would be part of a team during start-up and shutdown procedures. At all times they would be liaising and cooperating with other members of the team.
No licensing, legislative or certification requirements apply to this unit at the time of publication.
Elements and Performance Criteria
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 plant units being controlled | ||
1.6 | Note any outstanding/incomplete work | ||
1.7 | Check operational status of plant units being controlled | ||
2 | Interface with the control panel | 2.1 | Monitor the process using the operator interfaces and keep appropriate personnel informed on developments |
2.2 | Select appropriate controller modes to ensure the effective control of the process | ||
2.3 | Undertake required set point/output changes to optimise plant and process requirements | ||
2.4 | Access historical data and information | ||
2.5 | Acknowledge messages and alarms | ||
3 | Control the process using the local control system | 3.1 | Obtain relevant data and information from the control system by applying systems knowledge |
3.2 | Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults | ||
3.3 | Interpret alarms and prioritise steps to ensure control of system is maintained | ||
3.4 | Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics | ||
3.5 | Make required set point/output changes to meet plant and process requirements | ||
3.6 | Take other appropriate action as required | ||
3.7 | Record process variations/irregularities in accordance with procedures | ||
4 | Facilitate planned and unplanned process start-ups and shutdowns | 4.1 | Respond to all alarms and take appropriate action |
4.2 | Maintain coordination with all outside services and operations in order to assist in the correct identification and reporting of faults | ||
4.3 | Conduct planned start-up and shutdown processes to procedures | ||
4.4 | Conduct unplanned start-up and shutdown processes to procedures | ||
4.5 | Communicate with all operational areas and personnel affected by unplanned events to ensure safety is maintained during the process | ||
4.6 | Implement all required and stated emergency responses and ensure the outcomes of these responses are communicated to all affected areas | ||
4.7 | Log all required information for further action to provide a historical record of all events | ||
Evidence of Performance
Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and demonstrate the ability to:
identify job requirements
obtain and interpret data from the control system
monitor and control individual items of equipment to meet specifications
conduct planned and unplanned start-ups and shutdowns according to procedures
recognise early warning signs of equipment/processes needing attention or with potential problems
determine the most likely cause of routine problems
take appropriate action to ensure a timely return to full performance
distinguish between causes of problems/alarms/fault indications, such as:
instrument failure/malfunction
electrical failure/malfunction
mechanical failure/malfunction
equipment design deficiencies
product parameters (temperature, flows, pressure and levels)
identify hazards and apply hazard control procedures
complete workplace forms
communicate with team and supervisors.
Evidence of Knowledge
Evidence must be provided that demonstrates knowledge of:
all items on a schematic of the controller and the function of each
principles of operation and location of the process/production equipment
specific plant process operations
product specifications and tolerances
systems operating parameters
basis of control for the process
emergency shutdown procedures
process-specific science (physics, chemistry and biochemistry) to the level required to recognise and resolve routine problems
mathematics to the level required to interpret control data, recognise trends and take appropriate action
process drawings, e.g. piping and instrumentation diagram (P&ID), process flow diagram (PFD) and cause and effect
instrumentation and control systems, e.g. relevant primary sensing devices, final control elements, transducers/transmitters
simple control loops, including proportional integral derivative (PID) control, set points, controlled variable and indicated variable
organisation procedures
hazards that may arise in the job/work environment, and:
their possible causes
potential consequences
appropriate risk controls.
Assessment Conditions
The unit should be assessed holistically and the judgement of competence based on a holistic assessment of the evidence.
It may be appropriate to assess this unit concurrently with units such as:
teamwork
communication
safety
The collection of performance evidence:
should occur over a range of situations which include typical disruptions to normal, smooth operation of an operating plant
will typically include a supervisor/third-party report or other evidence, 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
may include the use of an appropriate local controller controlling an industrial plant requiring demonstration of operation, start-up and shutdown procedures and responding to problems
may use an appropriate local controller linked to a simulator which simulates an industrial plant requiring demonstration of operation, start-up and shutdown procedures and responding to problems
may use industry-based simulation for all or 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 shall 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.
Current industry skills are the knowledge, skills and experience required by VET trainers and assessors and those who provide training and assessment under supervision to ensure that their training and assessment is based on current industry practices and meets the needs of industry.
Current industry skills may be informed by consultations with industry and may include, but is not limited to:
having knowledge of and/or experience using the latest techniques and processes
possessing a high level of product knowledge
understanding and knowledge of legislation relevant to the industry and to employment and workplaces
being customer/client-oriented
possessing formal industry and training qualifications
training content that reflects current industry practice.
Foundation Skills
This section describes those language, literacy, numeracy and employment skills that are essential to performance.
Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.
Range Statement
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, and 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. |
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) 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 |
Routine problems | Routine problems must be resolved by applying known solutions. Routine problems are predictable and include one or more of the following: 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 loss of power/utilities Known solutions are drawn from one or more of the following: procedures training remembered experience Non-routine problems must be reported according to according to relevant procedures. |
Operate | Operate is to monitor, adjust/change the plant item/unit/system to meet specifications, by: using local controller in the plant |
Operator interfaces | Operator interfaces include one or more of the following: keyboards/key pads track ball/mouse touch screen monitor standalone devices |
Equipment | This unit includes all items of equipment which form part of the production/processing system. Equipment will be selected as required from the following: plant items requiring only simple control programmable logic controllers (PLCs) hard wired control and alarm panels analogue control systems personal computers printers fire and gas detection/protection systems emergency shutdown systems communications systems |
Appropriate action | Appropriate action includes the following: 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 |
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 all other conditions experienced on the plant (i.e. from any condition to any condition experienced on the plant) |
Sectors
Competency Field
Operations