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Evidence Guide: PMAOPS301B - Produce product by distillation

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

 

PMAOPS301B - Produce product by distillation

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 distillation system.

  1. Perform pre-start up checks
  2. Bring into operation equipment required for distillation
  3. Correctly sequence all equipment required before commencing the process
  4. Monitor temperature increase during start up and take appropriate action
  5. Stabilise distillation system to produce specified rate and quality within minimum time.
Perform pre-start up checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Bring into operation equipment required for distillation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Correctly sequence all equipment required before commencing the process

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor temperature increase during start up and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Stabilise distillation system to produce specified rate and quality within minimum time.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor distillation process.

  1. Continually monitor process systems to ensure that product specifications are maintained
  2. Minimise the risk of product specification deviations during the process by applying process knowledge
  3. Adjust process variables to ensure the product remains within specification
  4. Identify issues likely to impact on plant performance and take appropriate action
  5. Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people
  6. Record product movements as a historical record of the quantity and quality of the finished product.
Continually monitor process systems to ensure that product specifications are maintained

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Minimise the risk of product specification deviations during the process by applying process knowledge

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust process variables to ensure the product remains within specification

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify issues likely to impact on plant performance and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Predict impact of a change in one unit/area on other plant units/areas and communicate this to relevant people

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record product movements as a historical record of the quantity and quality of the finished product.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change production rates and/or product specification.

  1. Predict the need to make change to meet process requirements
  2. Manipulate unit temperatures to achieve product specifications
  3. Trim plant in a manner which prepares it for the transition
  4. Manage transitions smoothly and in a timely manner
  5. Minimise out of specification material as a result of a transition.
Predict the need to make change to meet process requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manipulate unit temperatures to achieve product specifications

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Trim plant in a manner which prepares it for the transition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manage transitions smoothly and in a timely manner

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Minimise out of specification material as a result of a transition.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down distillation systems.

  1. Determine type of shut down required
  2. Give advanced warning of shut down where possible
  3. Change over individual items of equipment
  4. Shut down individual items of equipment and the entire reaction system
  5. Shut down to a stand-by condition if required
  6. Shut down in an emergency when required
  7. Reset trips and alarms after a shut down
  8. Leave plant in a condition ready to restart
  9. Make plant safe for maintenance work where required.
Determine type of shut down required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Give advanced warning of shut down where possible

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change over individual items of equipment

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down individual items of equipment and the entire reaction system

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down to a stand-by condition if required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Shut down in an emergency when required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Reset trips and alarms after a shut down

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Leave plant in a condition ready to restart

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make plant safe for maintenance work where required.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare distillation unit for maintenance.

  1. Inform plant personnel of impending maintenance activity
  2. Prepare unit for maintenance/vessel entry as required according to procedures
  3. Test trips and alarms as required
  4. Accept plant back from maintenance
  5. Prepare plant for the introduction of process materials and operation.
Inform plant personnel of impending maintenance activity

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare unit for maintenance/vessel entry as required according to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Test trips and alarms as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Accept plant back from maintenance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Prepare plant for the introduction of process materials and operation.

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, 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 of 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 distillation units 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. Consider co-assessment with:

PMAOPS201B Operate fluid flow equipment

PMAOPS222B Operate and monitor pumping systems and equipment

PMAOPS205B Operate heat exchangers.

In a major hazard facility, it may be appropriate to assess this unit concurrently with:

MSAPMOHS200A Work safely.

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

Competence includes:

efficient and effective operation of plant/equipment

hazard analysis

completing plant records

communication

problem solving.

Competence also includes the ability to isolate the causes of problems to an item of equipment within the distillation system and to distinguish between causes of problems/alarm/fault indications such as:

process feed variations

instrument failure/wrong reading

electrical failure

mechanical failure

operational problem.

Required knowledge

The knowledge referred to in the Evidence Guide for this unit includes:

principles of operation of plant/equipment

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

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

process control philosophies and strategies

outside process/production operations, including column, tray/packing and reboiler operations, and distillation principles (including stripping and rectification)

heating and cooling principles

stabilisation principles

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

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.

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 of 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.

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.

Context

This unit of competency includes all such items of equipment and unit operations which form part of the distillation system. For your plant this may include (select relevant items):

columns/towers

trays/packing

boilers/reboilers

condensers

heat exchangers

refrigerant compressors

pumps

valves.

Typical problems for your plant may include:

flooding

channelling (packed column)

dumping

entrainment.

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.