Application
This unit of competency covers the skills and knowledge required to modify plant hardware.
This unit of competency applies to senior technicians or those in similar roles who are required to apply in-depth technical knowledge of process and plant operation in order to determine operational and technical requirements, develop technical specifications, evaluate options against specifications, select the most appropriate option, and coordinate and supervise the installation and commissioning of the modified equipment.
This unit does not apply to:
identification of the need for modification; the need for the modification may arise from a continuous improvement project, as a result of an analysis of plant performance or from any other source
design of equipment; this would typically be an engineering role
work requiring special certification (e.g. registered structural engineer)
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 | Confirm required outcomes from modification | 1.1 | Communicate with relevant technical, operational and other key personnel to determine operational and technical requirements of the plant modification |
1.2 | Determine regulatory/industry code requirements | ||
1.3 | Obtain relevant drawings of existing plant | ||
1.4 | Develop modification brief, including relevant plant schematic sketch, to meet needs | ||
1.5 | Establish required performance measures to indicate success of project | ||
1.6 | Obtain sign-off on modification brief from all relevant persons | ||
2 | Short list possible modifications to meet brief | 2.1 | Investigate the range of available equipment/plant units |
2.2 | Determine relative advantages and disadvantages between of each class of equipment/type of modification which may provide a solution | ||
2.3 | Compile a shortlist of modification types/equipment classes which will best meet the modification brief | ||
2.4 | Discuss shortlist alternatives with relevant stakeholders and obtain sign-off for the chosen approach | ||
3 | Select technically best equipment/unit/modification | 3.1 | Complete technical specification for required modification incorporating feedback received |
3.2 | Compare specification with that of 'off the shelf' equipment, where appropriate | ||
3.3 | Arrange for equipment suppliers to tender to the specification, where necessary, following company procedures | ||
3.4 | Rank competing items by their compliance with the technical specification | ||
4 | Compare hazard profile of possible modifications | 4.1 | Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the modification according to company procedures |
4.2 | Ensure that all stakeholders are represented on the hazard analysis team | ||
4.3 | Brief the hazard analysis team on the modification and the alternatives under evaluation | ||
4.4 | Eliminate alternatives which do not meet hazard requirements. | ||
4.5 | Rank remaining competing items by safety performance. | ||
5 | Make final choice of solution | 5.1 | Evaluate competing items by their economic performance (e.g. life, maintenance and running costs) and rank by total lifetime cost |
5.2 | Seek further information where necessary to allow a rational selection to be made | ||
5.3 | Choose the modification which meets all required minimum standards (regulatory, enterprise, output and economic) and will provide the best solution | ||
5.4 | Verify choice in discussion with production and engineering managers and other key stakeholders | ||
5.5 | Arrange for order to be placed, following company procedures | ||
6 | Check and commission modification | 6.1 | Undertake pre-commissioning activities |
6.2 | Complete safety acceptance documentation | ||
6.3 | Identify, record and report problems or non-conformances | ||
6.4 | Conduct trials/test runs | ||
6.5 | Record and report performance data | ||
6.6 | Bring the plant/plant systems/pipeline on line | ||
7 | Complete modification | 7.1 | Evaluate performance of modification |
7.2 | Make adjustments as required | ||
7.3 | Accept (or otherwise) the equipment/unit (and ensure payment flows) | ||
7.4 | Ensure plant procedures and training material updated | ||
7.5 | Ensure plant drawings and engineering specifications are updated | ||
7.6 | Complete all other required paperwork | ||
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:
determine options for modifications to address identified needs
determine agreed technical requirements, operations requirements, timelines, cost and other requirements for modifications
evaluate types of modification and classes of equipment against specifications, hazard and operability study (HAZOP), economic performance and legislative requirements to select best solution
undertake pre-commissioning activities, trials and evaluations and make adjustments, as required
ensure training, procedures, plant drawings and specifications are updated to reflect modifications.
Evidence of Knowledge
Evidence must be provided that demonstrates knowledge of:
the operations of the plant and each major unit in it
the principles of operation of the equipment being investigated to the extent required to interpret technical specifications in a meaningful manner
the basics of plant economics and whole of life costing
hazard analysis principles
typical hazards with the type of equipment being investigated
work health and safety (WHS) legislative requirements related to plant, including registration and documentation requirements related to modification of registered plant
systems operating parameters and integrity limits
process-specific science (physics, chemistry and biochemistry)
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 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
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 flow/pressure gas equipment failures noise, rotational equipment or vibration plant services (steam, condensate and cooling water) flammability and explosivity hazardous products and materials 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 |
Sectors
Competency Field
Operations