In a typical scenario an experienced operations technician would be a participant in a multi disciplinary team consisting of operators, engineers, safety and other personnel to review a change in plant, process or equipment to see if the change can cause unforeseen hazards or introduce unexpected operability problems and that the change meets the standards.

The operations technician would:

review pipe and instrumentation diagrams

identify possible hazards or operability issues

contribute to the safe and productive operation of the plant

recommend amendments to improve safety and operability of the proposed change

review and amend procedures in relation to the change

The operations technician would be an experienced operator of the plant under review and part of a HAZOP study team during all phases of the study, including at the initial concept stage, when the pipe and instrumental diagrams (PID) are available, during construction, installation and commissioning and during operation reviewing and amending procedures. He/she would be expected to be capable of demonstrating competence in all parts of this unit. He/she would be actively participating in all phases of the study, liaising and cooperating with other members of the team.

PMAOPS280B

Interpret process plant schematics

ELEMENT

PERFORMANCE CRITERIA

1. Identify the principles of a HAZOP study

1.1. Explain the purpose of a HAZOP

1.2. Describe the key steps in undertaking a HAZOP study

1.3. Identify the tools used in a HAZOP study

1.4. Describe how key words assist in identifying problems

1.5. Explain how HAZOP studies are applied in the workplace

2. Participate in a HAZOP study

2.1. Identify the purpose and operation of the new/modified equipment/process

2.2. Explain the normal operating conditions, method of operation and associated equipment and componentry of proposed change

2.3. Review relevant information to assist in the identification of possible problems

2.4. Process available information to identify potential hazards or operability issues

2.5. Identify potential hazards or operability issues and possible consequences utilising key words

2.6. Assess the risks arising from identified potential hazards or operability issues

2.7. Identify items needing further action

2.8. Review relevant operating and safety procedures

2.9. Recommend possible solutions to minimise risk of proposed change.

3. Complete delegated actions within scope of responsibility.

3.1. Perform delegated actions within area of responsibility

3.2. Follow initiated items through until final resolution has occurred

3.3. Identify problems needing further action

3.4. Determine possible fault causes within area of responsibility

3.5. Report outcomes to designated person.

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

This competency includes the following skills:

analysis

communication

instrument failure/malfunction

electrical failure/malfunction

mechanical failure/malfunction

equipment design deficiencies

product parameters (temperature, flows, pressure and levels)

process control system malfunction

power/utility failures.

An ability to operate the plant under review is considered to be an essential element of this unit of competency.

Required knowledge

The knowledge referred to in the evidence guide for this unit includes:

the architecture and location of the process/production equipment

specific plant process operations

interactions between plant items/processes

product specifications and tolerances

systems operating parameters

system integrity limits

process control philosophies and strategies

emergency shutdown procedures

process specific physics, chemistry and mathematics

basic science of upstream and downstream processes

impact of external factors (eg variations in weather, feed)

process drawings (eg P&ID, PFD, cause and effect)

basis of control for the plant/s

instrumentation and control systems, components and loops as they relate to the modification under review

impacts of changing process/production equipment settings and the limits within which changes can be made

organisation procedures

OHS, hazardous substances and environmental requirements

thorough knowledge of enterprise standard operating procedures, plant processes and equipment for area under review

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

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. Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.

Simulation may be required to allow for timely assessment of parts of this unit of competency (eg elements 1-2). Simulation should be based on an actual HAZOP study relevant to the plant and may include the use of case studies/scenarios and role plays.

This unit of competency requires an application of the knowledge contained in the use of the process control system and its 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 responses. 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:

potential problems are recognised

the range of possible causes can be identified and analysed and the most likely cause determined

key words are utilised in the identification of potential hazards or operability issues

possible consequences are identified and explained

risks are assessed from identified potential hazards or operability issues

appropriate contribution is made to the identification of potential hazards and operability issues and risk assessment.

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 HAZOP tools and relevant plant documentation 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, communication and leadership 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 italicized 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 AS61882, the latest version must be used.

Context

This unit of competency includes all relevant information and plant and equipment that might be required for the HAZOP study. This may include (select relevant items):

provisional layouts

material safety data sheets

process drawings (eg P&ID, PFD, cause and effect)

plant model

equipment arrangement drawings

provisional operating instructions/procedures

plant operating procedures

logic diagrams

equipment reference manuals

hazardous area layouts

start up and shut down emergency procedures

access to plant and equipment.

Typical HAZOP study for your plant may include:

purpose of new equipment/plant

how the design will cope with abnormal conditions

identification of potential hazards and operating issues.

Designated action

Designated action may include:

review of plant operating procedures

undertaking additional tasks from action list HAZOP report

attendance at HAZOP review meetings

recording results from additional tasks.

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.