In a typical scenario a technician will monitor plant for signs of corrosion and or monitor the concentration of inhibiting chemicals or similar. They will maintain an appropriate dosing regime in order to control the rate of corrosion.

Generally the operations technician would operate independently and be expected to be capable of performing all parts of this unit, however they may be part of a team during critical inspections or maintenance operations. At all times they would be liaising and cooperating with other members of the team.

ELEMENT

PERFORMANCE CRITERIA

1. Identify corrosion controls in use.

1.1. Identify sites susceptible to corrosion on work area

1.2. Explain the causes and effects of corrosion at these sites

1.3. Identify the corrosion inhibitor(s) used in work area

1.4. Determine hazards associated with corrosion and corrosion control

1.5. Control hazards associated with corrosion and corrosion control

1.6. Coordinate with appropriate personnel.

2. Dose corrosion inhibitor.

2.1. Monitor indicators of rate of corrosion as required

2.2. Monitor inhibitor dosing equipment as required

2.3. Adjust rate of dosing as required by procedures

2.4. Monitor inhibitor stocks as required

2.5. Recognise situations requiring action

2.6. Take appropriate action.

3. Test plant for corrosion as required

3.1. Identify corrosion testing methods used in work area

3.2. Complete testing activities as required by procedures

3.3. Examine test results and take appropriate action

4. Isolate and de-isolate dosing plant.

4.1. Isolate dosing plant

4.2. Make safe for required work

4.3. Check dosing plant is ready to be returned to service

4.4. Prepare dosing 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

the galvanic series

electrochemical corrosion

types of corrosion/causes of anode formation

factors controlling the rate of corrosion

types of corrosion inhibitors used and their action

hazards associated with corrosion inhibitors and relevant hazard controls

costs and hazards of corrosion

principles of operation of dosing equipment

physics and chemistry relevant to the process unit and the materials processed

process parameters and limits, eg temperature, pressure, flow, pH

duty of care obligations

hierarchy of control

routine problems, faults and their resolution

relevant alarms and actions

plant process idiosyncrasies

all items on a schematic of the plant item and the function of each

correct methods of starting, stopping, operating and controlling process

corrective action appropriate to the problem cause

function and troubleshooting of major components and their problems

types and causes of 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, role plays and 3D virtual reality interactive systems. In the case of evacuation training or training for competencies practised in life threatening situations, simulation may be used for the bulk of the training.

This unit of competency requires an application of the knowledge contained in the use of the corrosion control systems and their integral equipment, to the level needed to maintain control and recognise and resolve problems. This can 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.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the oracy, 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

This unit of competency includes all such items of equipment and unit operations which form part of the corrosion control system. For your plant/pipeline this may include:

dosing pumps

flow rate controllers

analytical instrumentation related to corrosion

head tanks

test coupons or similar

brushes

inspection devices

This unit does not include the operation of smart pigs - see PMAOPS335A Conduct pipeline pigging.

Work area

Work area refers to the systems or units the technician is responsible for and may be a plant area, a well head or pipeline covering thousands of kilometers.

Corrosion

Corrosion typically refers to any electrochemical process leading to the decay of metal. It may also be applied to decay processes in non-metals if appropriate.

Corrosion inhibitors

Corrosion inhibitors for metals are typically amines but may include:

anodic or cathodic inhibitors

film formers

oxygen scavengers

pH adjusters/buffers

biocides

additives and carriers such as:

solvent base

surfactants

dispersants

demulsifiers

de-foamers

other materials.

Inhibitor dosing

Inhibitor dosing may be continuous or batch injection of corrosion inhibitor to 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

Support/generic

This unit contains employability skills.