Application
This unit of competency covers the skills and knowledge required to operate a biochemical process and ancillary equipment to produce chemical or biological materials as product. It applies to biochemical processes that use enzymes, such as amylases; moulds, such as yeasts; and/or bacteria, such as e coli. It applies to batch and continuous processes.
Products could include industrial alcohol, corn starch, insulin or other industrial fermentation/biochemical processes. This unit applies to the biochemical conversion plant unit.
This unit of competency applies to operations technicians who are required to demonstrate a significant understanding of the process and the equipment operation in order to identify and rectify operational problems, predict the potential impact of changes from other plant sections on biochemical process, and facilitate output changes.
This unit of competency applies to an individual operating independently in a plant with local control or in liaison with the control room operator in a plant with a centralised control panel, such as distributed control system (DCS) type controls. In the case of large complex plant, the operations technician would be part of a team during start-up and shutdown procedures.
This unit of competency applies to an individual working alone or as part of a team or group and working in liaison with other shift team members and the control room operator, as appropriate.
This unit of competency does not require the operation of a central control panel.
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 biochemical unit | ||
1.6 | Note any outstanding/incomplete work | ||
1.7 | Check operational status of biochemical unit | ||
2 | Operate the biochemical processes | 2.1 | Describe the type of biochemical plant unit, the component plant items and their duties |
2.2 | Complete routine checks, logs and paperwork | ||
2.3 | Check performance of all ancillaries (such as mixing and heat exchange) | ||
2.4 | Recognise and interpret trends in bioreactor data/appearance | ||
2.5 | Recognise the signs of potential and actual problems | ||
2.6 | Identify the consequences to the bioreactor processes of the identified changes, trends and problems | ||
2.7 | Keep conditions within the optimum range | ||
2.8 | Take action to minimise the impact on health, safety and environment (HSE) and the business of potential and actual problems | ||
3 | Ramp output up/down | 3.1 | Predict from rates and schedule when a change will be required |
3.2 | Give advanced notice of change to work team | ||
3.3 | Prepare plant for the change | ||
3.4 | Predict the required amount of adjustment to cause the required change | ||
3.5 | Make the change in a controlled manner without excessive variation | ||
3.6 | Monitor the progress of the change and make minor adjustments as required | ||
4 | Diagnose and take action on abnormal situations in accordance with procedures | 4.1 | Monitor biochemical unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses. |
4.2 | Describe impacts of any changes upstream and downstream | ||
4.3 | Recognise actual and developing situations which may require action | ||
4.4 | Apply operational knowledge to resolve problems | ||
4.5 | Take other actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation. | ||
4.6 | Follow through items initiated until final resolution has occurred | ||
5 | Isolate and de-isolate biochemical unit and its component plant items | 5.1 | Complete any required pre-start checks |
5.2 | Start up/shut down biochemical unit according to its type and duty in liaison with other personnel | ||
5.3 | Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel | ||
5.4 | Isolate entire biochemical unit and/or any component plant item | ||
5.5 | Make safe for required work | ||
5.6 | Check biochemical unit/plant item is ready to be returned to service | ||
5.7 | De-isolate and prepare biochemical unit/plant item for return to service | ||
6 | Clean reactors/vessels | 6.1 | Identify cleaning requirements |
6.2 | Clean to requirements according to procedures | ||
6.3 | Retain microorganisms contained in the plant and prepare for reuse as appropriate | ||
6.4 | Dispose of waste materials according to procedures |
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 include the ability to:
use data and own senses to monitor plant and maximise performance
adjust processes parameters to meet product requirements
perform pre-start checks, start-up/shutdown procedures, and isolations and de-isolations
identify early warning signs of equipment/processes needing attention or with potential problems
identify hazards and risks and apply risk control procedures.
Evidence of Knowledge
Evidence must be provided that demonstrates knowledge of:
all items on a schematic of the system and functions of each
principles of operation of biochemical process and ancillary equipment
process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality
systems’ operating parameters, integrity limits, including feed, desired output, temperature, agitation, aeration (if appropriate), microorganism/enzyme, product tolerances, and impact of external factors (e.g. variations in weather and feed)
function and troubleshooting of major components and their problems
hierarchy of control
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.
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 biochemical process and equipment allowing operation
may use industry-based simulation for 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 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.
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. |
Hazards | Hazards include one or more of the following: electricity gas 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, 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 are predictable and have known solutions and include one or more of the following: sudden changes in feed (rate, composition, concentration) changes in required production rate changes in ambient conditions (e.g. summer to winter operation) handling a plant shutdown without allowing the microorganisms to die control of degree of agitation settling/removal/recycling of microorganisms feed variations instrument failure/wrong reading electrical failure mechanical failure operational problem |
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 |
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 other conditions/situations experienced on the plant |
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 |
Operate | Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or both of the following: manually in the plant using local controller in the plant |
Product | Product includes anything produced by a process step and so includes: intermediate products, such as the product from one process step, which then becomes the feed for another |
Bioreactor system | This unit of competency includes all such items of ancillary equipment and unit operations which form part of the bioreactor system. A unit/system comprises two or more components of plant/equipment that are operated together to produce product, including as appropriate to the facility, one or more of the following: pumps (feed and dosing pumps) utilities and services, such as air agitators air/gas supply and/or removal temperature control equipment, such as heaters, coolers and heat exchangers other equipment integral to the operation of the bioreactor system |
Sectors
Competency Field
Operations