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Evidence Guide: PMAOPS217B - Operate wet milling equipment

Student: __________________________________________________

Signature: _________________________________________________

Tips for gathering evidence to demonstrate your skills

The important thing to remember when gathering evidence is that the more evidence the better - that is, the more evidence you gather to demonstrate your skills, the more confident an assessor can be that you have learned the skills not just at one point in time, but are continuing to apply and develop those skills (as opposed to just learning for the test!). Furthermore, one piece of evidence that you collect will not usualy demonstrate all the required criteria for a unit of competency, whereas multiple overlapping pieces of evidence will usually do the trick!

From the Wiki University

 

PMAOPS217B - Operate wet milling equipment

What evidence can you provide to prove your understanding of each of the following citeria?

Prepare for work.

  1. Identify work requirements
  2. Identify and control hazards
  3. Coordinate with appropriate personnel
Identify work requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and control hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up mill.

  1. Perform pre-start-up checks
  2. Liaise with other team members and control room operator on the intended function
  3. Confirm raw materials are available and correct
  4. Prepare pre-mixer and introduce raw materials to pre-mixer (if required)
  5. Start up the mill as needed
  6. Build operating rate steadily, checking expected performance criteria at various stages
  7. Bring to specified conditions within specified time.
Perform pre-start-up checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Liaise with other team members and control room operator on the intended function

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Confirm raw materials are available and correct

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare pre-mixer and introduce raw materials to pre-mixer (if required)

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up the mill as needed

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Build operating rate steadily, checking expected performance criteria at various stages

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Bring to specified conditions within specified time.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor milling operation.

  1. Monitor and observe mill operating condition, pressures and temperatures
  2. Recognise observations which differ from normal operating parameters and requirements
  3. Take appropriate action to maintain correct operating parameters
  4. Identify faults and initiate repair or report as required
  5. Monitor life of beads (if applicable) and/or condition of rollers/balls (if applicable).
Monitor and observe mill operating condition, pressures and temperatures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise observations which differ from normal operating parameters and requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to maintain correct operating parameters

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify faults and initiate repair or report as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor life of beads (if applicable) and/or condition of rollers/balls (if applicable).

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down and start up milling equipment.

  1. Determine type of shutdown required
  2. Check for related work or other affected plant to allow for coordination of activities and give advance warning where possible
  3. Check and satisfy all permit requirements before equipment is brought back on line
  4. Monitor and report equipment performance to control operations
  5. Complete logs recording the details of the work conducted to provide a historical record of the equipment operation.
Determine type of shutdown required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for related work or other affected plant to allow for coordination of activities and give advance warning where possible

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check and satisfy all permit requirements before equipment is brought back on line

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor and report equipment performance to control operations

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete logs recording the details of the work conducted to provide a historical record of the equipment operation.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate and de-isolate plant.

  1. Isolate plant
  2. Make safe for required work
  3. Check plant is ready to be returned to service
  4. Prepare plant for return to service.
Isolate plant

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make safe for required work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check plant is ready to be returned to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare plant for return to service.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

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 that 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 and role plays.

This unit of competency requires a significant body of knowledge which will 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

pre-start checks are made to ensure equipment is lined up to the plant in accordance with procedures and/or manufacturers specifications

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 that 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 that 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.

Required Skills and Knowledge

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.

Ability to distinguish between causes of problems/alarms/fault indications such as:

equipment malfunction, including consequences and potential for escalation

plant not performing to design

bead life, roller/ball wear or adjustment (as applicable).

Required knowledge

Demonstration of competence in this unit must include knowledge of:

all items on a schematic of the mill system and the function/s of each

principles of milling equipment operation

process and product variables

bead life (if beads are used in process).

physics and chemistry relevant to the process unit

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

duty of care obligations

hierarchy of control

communication protocols, eg radio, phone, computer, paper, permissions/authorities

routine problems, faults and their resolution

relevant alarms and actions

plant process idiosyncrasies

correct methods of starting, stopping, operating and controlling mill

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.

Range Statement

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 various types of wet milling equipment (select the types relevant to your plant):

vertical

horizontal

bead mills

roll/ball-type mills.

Ancillary equipment

This unit also covers ancillary equipment which form part of the wet milling system. For your plant this may include (select relevant items):

pre-mix vessels

coolers, cooling jackets and heat exchangers

pumps

vessels, tanks

piping systems

valves and flanges

sumps and drains.

Problems

Typical problems for your plant may include:

condition and life of beads (if applicable)

condition of rollers/balls (if applicable)

cooling system fouling

blocked filters or piping

high/low levels

loss of process cooling resulting in high process temperatures

equipment failure or shutdown resulting in loss of feed to process

excess/unexpected sand production

composition changes.

Start up shut down as required

Start up shut down as required includes:

start up and shut down to/from normal operating conditions

start up and shut down to/from isolated, cold, empty

all other conditions experienced on the plant.

ie from any condition to any condition experienced on 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.