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Evidence Guide: PMAOPS302 - Operate reactors and reaction 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

 

PMAOPS302 - Operate reactors and reaction equipment

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

Prepare for work

  1. Receive and give shift handover
  2. Identify work requirements
  3. Identify and control hazards
  4. Coordinate with appropriate personnel
  5. Check for recent work undertaken on reactor unit
  6. Note any outstanding/incomplete work
  7. Check operational status of reactor unit
Receive and give shift handover

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify work requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify and control hazards

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check for recent work undertaken on reactor unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Note any outstanding/incomplete work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check operational status of reactor unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Operate reactor unit in accordance with procedures

  1. Describe the type of reactor unit, the component plant items and their duties
  2. Complete routine checks, logs and paperwork taking action on unexpected readings
  3. Change rate, grade or specification smoothly
  4. Manage transitions smoothly and in a timely manner to minimise scrap/off grade as a result of a transition
  5. Adjust reactor unit and its component plant items as appropriate to their type and duty to maximise performance
  6. Charge/discharge reactor, if appropriate
  7. Monitor condition of catalyst, if appropriate, and take action to maintain production schedule and quality
  8. Monitor materials and stock levels of fees and take action to maintain production schedule and quality.
Describe the type of reactor unit, the component plant items and their duties

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete routine checks, logs and paperwork taking action on unexpected readings

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Change rate, grade or specification smoothly

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Manage transitions smoothly and in a timely manner to minimise scrap/off grade as a result of a transition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust reactor unit and its component plant items as appropriate to their type and duty to maximise performance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Charge/discharge reactor, if appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor condition of catalyst, if appropriate, and take action to maintain production schedule and quality

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor materials and stock levels of fees and take action to maintain production schedule and quality.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Diagnose and take action on abnormal situations

  1. Monitor reactor unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses
  2. Describe impacts of any changes upstream and downstream
  3. Recognise actual and developing situations which may require action
  4. Apply operational knowledge to resolve problems
  5. Take actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation
  6. Follow through items initiated until final resolution has occurred
Monitor reactor unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Describe impacts of any changes upstream and downstream

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Recognise actual and developing situations which may require action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Apply operational knowledge to resolve problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Follow through items initiated until final resolution has occurred

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate and de-isolate reactor unit and its component plant items

  1. Complete any required pre-start checks
  2. Start up/shut down reactor unit according to the reactor type and duty in liaison with other personnel
  3. Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel
  4. Build reaction rate steadily and stabilise reaction system to produce in specification product at specified rates within minimum time
  5. Isolate entire reactor unit and/or any component plant item
  6. Make safe for required work
  7. Check reactor unit/plant item is ready to be returned to service
  8. De-isolate and prepare reactor unit/plant item for return to service
Complete any required pre-start checks

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up/shut down reactor unit according to the reactor type and duty in liaison with other personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Build reaction rate steadily and stabilise reaction system to produce in specification product at specified rates within minimum time

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Isolate entire reactor unit and/or any component plant item

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make safe for required work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check reactor unit/plant item is ready to be returned to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

De-isolate and prepare reactor unit/plant item for return to service

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean reactors/vessels in accordance with procedures

  1. Identify cleaning requirements
  2. Clean to requirements
Identify cleaning requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Clean to requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Assessed

Teacher: ___________________________________ Date: _________

Signature: ________________________________________________

Comments:

 

 

 

 

 

 

 

 

Instructions to Assessors

Evidence Guide

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare for work

1.1

Receive and give shift handover

1.2

Identify work requirements

1.3

Identify and control hazards

1.4

Coordinate with appropriate personnel

1.5

Check for recent work undertaken on reactor unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of reactor unit

2

Operate reactor unit in accordance with procedures

2.1

Describe the type of reactor unit, the component plant items and their duties

2.2

Complete routine checks, logs and paperwork taking action on unexpected readings

2.3

Change rate, grade or specification smoothly

2.4

Manage transitions smoothly and in a timely manner to minimise scrap/off grade as a result of a transition

2.5

Adjust reactor unit and its component plant items as appropriate to their type and duty to maximise performance

2.6

Charge/discharge reactor, if appropriate

2.7

Monitor condition of catalyst, if appropriate, and take action to maintain production schedule and quality

2.8

Monitor materials and stock levels of fees and take action to maintain production schedule and quality.

3

Diagnose and take action on abnormal situations

3.1

Monitor reactor unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses

3.2

Describe impacts of any changes upstream and downstream

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

3.6

Follow through items initiated until final resolution has occurred

4

Isolate and de-isolate reactor unit and its component plant items

4.1

Complete any required pre-start checks

4.2

Start up/shut down reactor unit according to the reactor type and duty in liaison with other personnel

4.3

Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel

4.4

Build reaction rate steadily and stabilise reaction system to produce in specification product at specified rates within minimum time

4.5

Isolate entire reactor unit and/or any component plant item

4.6

Make safe for required work

4.7

Check reactor unit/plant item is ready to be returned to service

4.8

De-isolate and prepare reactor unit/plant item for return to service

5

Clean reactors/vessels in accordance with procedures

5.1

Identify cleaning requirements

5.2

Clean to requirements

Required Skills and Knowledge

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare for work

1.1

Receive and give shift handover

1.2

Identify work requirements

1.3

Identify and control hazards

1.4

Coordinate with appropriate personnel

1.5

Check for recent work undertaken on reactor unit

1.6

Note any outstanding/incomplete work

1.7

Check operational status of reactor unit

2

Operate reactor unit in accordance with procedures

2.1

Describe the type of reactor unit, the component plant items and their duties

2.2

Complete routine checks, logs and paperwork taking action on unexpected readings

2.3

Change rate, grade or specification smoothly

2.4

Manage transitions smoothly and in a timely manner to minimise scrap/off grade as a result of a transition

2.5

Adjust reactor unit and its component plant items as appropriate to their type and duty to maximise performance

2.6

Charge/discharge reactor, if appropriate

2.7

Monitor condition of catalyst, if appropriate, and take action to maintain production schedule and quality

2.8

Monitor materials and stock levels of fees and take action to maintain production schedule and quality.

3

Diagnose and take action on abnormal situations

3.1

Monitor reactor unit and its component plant items frequently and critically throughout shift using measured/indicated data and senses

3.2

Describe impacts of any changes upstream and downstream

3.3

Recognise actual and developing situations which may require action

3.4

Apply operational knowledge to resolve problems

3.5

Take actions on abnormal situations which cannot be resolved during the shift to ensure safety and the resolution of the situation

3.6

Follow through items initiated until final resolution has occurred

4

Isolate and de-isolate reactor unit and its component plant items

4.1

Complete any required pre-start checks

4.2

Start up/shut down reactor unit according to the reactor type and duty in liaison with other personnel

4.3

Start up/shut down/changeover component plant items within unit according to their type and duty in liaison with other personnel

4.4

Build reaction rate steadily and stabilise reaction system to produce in specification product at specified rates within minimum time

4.5

Isolate entire reactor unit and/or any component plant item

4.6

Make safe for required work

4.7

Check reactor unit/plant item is ready to be returned to service

4.8

De-isolate and prepare reactor unit/plant item for return to service

5

Clean reactors/vessels in accordance with procedures

5.1

Identify cleaning requirements

5.2

Clean to requirements

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:

use data and own senses to monitor plant and maximise performance

perform pre-start checks, start-up/shutdown and cleaning procedures, and isolations and de-isolations

predict impact of a change in one unit/area on other plant units/areas and take appropriate action

identify hazards and risks and apply risk control procedures

identify early warning signs of equipment/processes needing attention or with potential problems

resolve routine and non-routine problems

use schematics and data to monitor plant and optimise performance

identify hazards and risks and apply risk control procedures.

Evidence must be provided that demonstrates knowledge of:

all items on a schematic of the production unit and functions, and troubleshooting of major components and their problems

principles of operation of plant/equipment:

basis of the process used in the production unit to cause chemical reaction

methods of controlling the reaction rate and yield and the advantages and disadvantages of each

impact of external factors (e.g. variations in weather and feed)

interactions between plant items/processes

process-specific science (physics, chemistry and biochemistry) to the level of being able to interpret the science and extract factors controlling the process and product and by-product production rate and quality (e.g. for chemistry interpret the equation for factors controlling rate and yield and also interfering reactions, such as salts and hydrates)

the nature/condition of materials at each stage of the reaction, the changes which have occurred in that stage and why they have occurred

the reaction in chemical terms and equations, including the effect of changing reaction variables (e.g. temperature, pressure, catalyst, concentration and pH)

systems’ operating parameters and integrity limits, including temperature, pressure, flow and pH

product specifications and tolerances

routine and non-routine problems that may arise, the range of possible causes and processes to develop solutions

hierarchy of control

hazards that may arise in the job/work environment, and:

their possible causes

potential consequences

appropriate risk controls.

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)

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

Situations requiring action

Situations requiring action include one or more of the following:

variations in catalyst activity

control of exotherm/endotherm

adjustments to meet product specifications

variations in feed rates/quality

raw materials variations

instrument failure/wrong reading

equipment failure (electrical/mechanical)

mechanical failure

operational problems

Actions on abnormal situations includes the following:

determine problems needing action

determine possible fault causes

develop solutions to problems which do not have a known solution

follow through items initiated until final resolution has occurred

report problems outside area of responsibility to designated person

Operational knowledge includes one or more of the following:

procedures

training

technical information such as journals, engineering specifications

remembered experience

relevant knowledge obtained from appropriate people

Start up/shut down

Start up/shut down includes the following:

start up and shut down to/from normal operating conditions

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

start up and shut down to/from other conditions/situations experienced on the plant

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

Operate

Operate is to monitor, adjust/make change to the production unit and/or its component items to meet specifications, by one or more of the following:

manually in the plant

using local controller in the plant

Product

Product includes anything produced by a process step and so includes:

intermediate products, such as the product from one process step, which then becomes the feed for another