Application
This unit of competency covers the skills and knowledge required to commission new plant/pipeline or recommission significantly modified plant/pipeline. It applies to plant/pipeline, such as on or offshore plant, wellheads, transmission pipelines or similar.
Commissioning refers to the start-up of a new plant or plant unit and the associated equipment for the first time. Recommissioning refers to the start-up of an existing plant following major modifications, rebuild or reconfiguration.
This unit of competency applies to senior technicians and those in similar roles who are required to apply in-depth knowledge of process and plant in order to ensure design of new/modified plant meets safety and operability requirements, plan and coordinate commissioning/recommissioning, and complete required documentation. The technician would not normally have a 'hands on' operating role for all items of equipment, but may have a 'hands on' role for major items of equipment; however this is not required as part of this competency.
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 | Contribute to/review the design of plant/ equipment | 1.1 | Apply process understanding to the design process |
1.2 | Identify the role and purpose of the plant and equipment | ||
1.3 | Ensure design meets the identified need | ||
1.4 | Identify process conditions and apply to hazard and operability studies (HAZOP) | ||
1.5 | Undertake investigations following hazard studies | ||
1.6 | Record and report findings | ||
2 | Take part in commissioning planning | 2.1 | Ensure the work is coordinated effectively with others involved on the work site |
2.2 | Obtain materials necessary to complete the work and check against job requirements | ||
2.3 | Obtain tools and equipment necessary to carry out the work and check for correct operation and safety | ||
2.4 | Prepare plans to ensure that procedures are performed in the correct sequence | ||
2.5 | Obtain approvals, where necessary, from appropriate authorities | ||
3 | Participate in acceptance of plant/ equipment | 3.1 | Undertake pre-commissioning activities |
3.2 | Complete safety acceptance documentation | ||
3.3 | Identify, record and report problems or non-conformance | ||
3.4 | Conduct trials/test runs | ||
3.5 | Record and report performance data | ||
4 | Commission system | 4.1 | Bring the plant/plant systems/pipeline online |
4.2 | Make and report adjustments | ||
4.3 | Prepare reports in accordance with legislative and company requirements to maintain the historical record | ||
5 | Evaluate results and identify modifications | 5.1 | Identify modifications and improvements required |
5.2 | Check specifications, procedures and training material match the final system/procedures | ||
5.3 | Complete documentation and report to appropriate personnel | ||
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:
plan, coordinate and monitor pre-commissioning, commissioning/recommissioning activities
arrange resources as required
communicate effectively with stakeholders, including manufacturers, engineering personnel, designers, contractors and maintenance and other company personnel
participate in and/or review hazard and operability studies (HAZOP), hazard analysis studies (HAZAN) or similar techniques
participate in and/or review design or modification plans
identify hazards and risks and apply risk control procedures
complete written/electronic documentation.
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 items of equipment in the system
principles of operation of instrumentation
principles of basic control systems
process control philosophies and strategies
interactions between plant items/processes
systems’ operating parameters
system integrity limits
product tolerances, limitations and specifications
types and purpose of typical pre-commissioning activities, including:
checking plant is built to design
ensuring plant is safe to operate
ensuring plant area and plant internals are clean and clear of debris
functional checking of equipment and ancillaries
types and purpose of typical commissioning/recommissioning activities, including:
trial running of equipment
use of trial materials in plant
safe introduction of process materials to plant
producing product within specification
bringing plant to design rates
solving operational problems
disposal of waste generated in the start-up
science (e.g. physics, chemistry and biochemistry) relevant to process and materials
process parameters and limits (e.g. temperature, pressure, flow and pH)
correct methods of starting, stopping, operating and controlling plant
routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions.
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 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) limited head spaces or overhangs 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 |
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 |
Documentation | Documentation includes one or more of the following: operating procedures work health and safety (WHS) and environmental legislative requirements manufacturer specifications appropriate authority approvals (e.g. local councils, road authority, sewerage, stormwater, electricity, water and telephone) quality assurance inspection and test reports |
Plant/pipeline systems | This unit of competency includes all items of equipment and unit operations which form part of the pipeline system including, as relevant to a particular plant/pipeline: pipes valves operating units electrical and electronic components programmable logic controllers (PLCs)/distributed control system (DCS) or other plant controls cathodic protection (CP) pressure/flow/temperature, regulation and meters |
Tools, materials and equipment | Tools, materials and equipment include one or more of the following: hand tools, power operated tools plant emergency equipment electrical and electronic test equipment gas detectors air compressor water pump |
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