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Evidence Guide: PMAOPS305 - Operate process control systems

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

 

PMAOPS305 - Operate process control systems

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 plant units being controlled
  6. Note any outstanding/incomplete work
  7. Check operational status of plant units being controlled
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 plant units being controlled

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Note any outstanding/incomplete work

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check operational status of plant units being controlled

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use operator interface

  1. Use human interface devices to access control system/panel
  2. Monitor the process using the operator interfaces
  3. Select appropriate controller modes
  4. Access historical data and information
  5. Acknowledge messages and alarms
Use human interface devices to access control system/panel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor the process using the operator interfaces

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select appropriate controller modes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Access historical data and information

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Acknowledge messages and alarms

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Access control information

  1. Obtain relevant data and information from the control system by applying systems knowledge
  2. Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults
  3. Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics
  4. Record process variations/irregularities to procedures
Obtain relevant data and information from the control system by applying systems knowledge

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record process variations/irregularities to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Control process variations and monitor operations

  1. Use historical data to assist the identification of problems
  2. Process available information to identify potential faults
  3. Undertake required set point/output changes to meet plant and process requirements
  4. Optimise plant operating conditions in accordance with guidelines
  5. Adjust production in response to test results and control panel information
  6. Monitor key process and environmental variables and take appropriate action
  7. Adjust controller settings in accordance with procedures
  8. Use fine tuning software as appropriate.
  9. Coordinate with upstream and downstream units as appropriate
  10. Record adjustments and variations to specifications/schedules
  11. Communicate to appropriate personnel as required
Use historical data to assist the identification of problems

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Process available information to identify potential faults

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Undertake required set point/output changes to meet plant and process requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Optimise plant operating conditions in accordance with guidelines

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust production in response to test results and control panel information

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Monitor key process and environmental variables and take appropriate action

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Adjust controller settings in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Use fine tuning software as appropriate.

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Coordinate with upstream and downstream units as appropriate

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record adjustments and variations to specifications/schedules

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Communicate to appropriate personnel as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Facilitate planned and unplanned process start-ups and shutdowns

  1. Select and apply procedures to planned start-up and shutdown processes
  2. Select and apply procedures to unplanned shutdown processes
  3. Implement all required emergency responses
  4. Communicate necessary information to all personnel affected by events
  5. Log all required information
Select and apply procedures to planned start-up and shutdown processes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select and apply procedures to unplanned shutdown processes

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Implement all required emergency responses

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Communicate necessary information to all personnel affected by events

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Log all required information

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Respond to alarms or out of specification conditions

  1. Identify system(s) affected by the alarm or condition
  2. Interpret alarms and prioritise actions to be taken
  3. Take appropriate action to respond to the alarm or incident
  4. Deal with any out-of-specification material in accordance with procedures
  5. Communicate the problem/solution to appropriate personnel
  6. Record the information as required
  7. Provide details of the alarm and action taken to the next shift at changeover
Identify system(s) affected by the alarm or condition

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Interpret alarms and prioritise actions to be taken

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Take appropriate action to respond to the alarm or incident

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Deal with any out-of-specification material in accordance with procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Communicate the problem/solution to appropriate personnel

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Record the information as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Provide details of the alarm and action taken to the next shift at changeover

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 plant units being controlled

1.6

Note any outstanding/incomplete work

1.7

Check operational status of plant units being controlled

2

Use operator interface

2.1

Use human interface devices to access control system/panel

2.2

Monitor the process using the operator interfaces

2.3

Select appropriate controller modes

2.4

Access historical data and information

2.5

Acknowledge messages and alarms

3

Access control information

3.1

Obtain relevant data and information from the control system by applying systems knowledge

3.2

Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults

3.3

Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics

3.4

Record process variations/irregularities to procedures

4

Control process variations and monitor operations

4.1

Use historical data to assist the identification of problems

4.2

Process available information to identify potential faults

4.3

Undertake required set point/output changes to meet plant and process requirements

4.4

Optimise plant operating conditions in accordance with guidelines

4.5

Adjust production in response to test results and control panel information

4.6

Monitor key process and environmental variables and take appropriate action

4.7

Adjust controller settings in accordance with procedures

4.8

Use fine tuning software as appropriate.

4.9

Coordinate with upstream and downstream units as appropriate

4.10

Record adjustments and variations to specifications/schedules

4.11

Communicate to appropriate personnel as required

5

Facilitate planned and unplanned process start-ups and shutdowns

5.1

Select and apply procedures to planned start-up and shutdown processes

5.2

Select and apply procedures to unplanned shutdown processes

5.3

Implement all required emergency responses

5.4

Communicate necessary information to all personnel affected by events

5.5

Log all required information

6

Respond to alarms or out of specification conditions

6.1

Identify system(s) affected by the alarm or condition

6.2

Interpret alarms and prioritise actions to be taken

6.3

Take appropriate action to respond to the alarm or incident

6.4

Deal with any out-of-specification material in accordance with procedures

6.5

Communicate the problem/solution to appropriate personnel

6.6

Record the information as required

6.7

Provide details of the alarm and action taken to the next shift at changeover

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 plant units being controlled

1.6

Note any outstanding/incomplete work

1.7

Check operational status of plant units being controlled

2

Use operator interface

2.1

Use human interface devices to access control system/panel

2.2

Monitor the process using the operator interfaces

2.3

Select appropriate controller modes

2.4

Access historical data and information

2.5

Acknowledge messages and alarms

3

Access control information

3.1

Obtain relevant data and information from the control system by applying systems knowledge

3.2

Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults

3.3

Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics

3.4

Record process variations/irregularities to procedures

4

Control process variations and monitor operations

4.1

Use historical data to assist the identification of problems

4.2

Process available information to identify potential faults

4.3

Undertake required set point/output changes to meet plant and process requirements

4.4

Optimise plant operating conditions in accordance with guidelines

4.5

Adjust production in response to test results and control panel information

4.6

Monitor key process and environmental variables and take appropriate action

4.7

Adjust controller settings in accordance with procedures

4.8

Use fine tuning software as appropriate.

4.9

Coordinate with upstream and downstream units as appropriate

4.10

Record adjustments and variations to specifications/schedules

4.11

Communicate to appropriate personnel as required

5

Facilitate planned and unplanned process start-ups and shutdowns

5.1

Select and apply procedures to planned start-up and shutdown processes

5.2

Select and apply procedures to unplanned shutdown processes

5.3

Implement all required emergency responses

5.4

Communicate necessary information to all personnel affected by events

5.5

Log all required information

6

Respond to alarms or out of specification conditions

6.1

Identify system(s) affected by the alarm or condition

6.2

Interpret alarms and prioritise actions to be taken

6.3

Take appropriate action to respond to the alarm or incident

6.4

Deal with any out-of-specification material in accordance with procedures

6.5

Communicate the problem/solution to appropriate personnel

6.6

Record the information as required

6.7

Provide details of the alarm and action taken to the next shift at changeover

Evidence required to demonstrate competence in this unit must be relevant to and satisfy the requirements of the elements and performance criteria, and demonstrate the ability to:

identify and control hazards

use schematics and data to monitor plant and optimise performance

isolate the causes of problems and distinguish between causes of problems/alarm/fault indications, including:

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

communicate effectively with team, group, supervisors and other personnel

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

take appropriate action to ensure a timely return to full performance

select and apply planned and unplanned start-up shutdown procedures

identify and communicate information required by others

complete written records.

Evidence must be provided that demonstrates knowledge of:

organisation procedures

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

their possible causes

potential consequences

appropriate risk controls

the function and location of the process/production equipment

interactions between plant items/processes

product specifications and tolerances

systems’ operating parameters

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

system integrity limits

process control philosophies and strategies

emergency shutdown procedures

specific plant process operations

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)

basic science of upstream and downstream processes

emergency shutdown procedures

process drawings, such as piping and instrumentation diagram (P&ID) and process flow diagram (PFD )

cause and effect

control system architecture

basis of control for the plant/s

types of instrumentation and control systems, including feed forward, feedback and open control

types of instrumentation and control system components and their role, including primary sensing devices, final control elements and transducers/transmitters

how control loops and their components, including PID control, set points, controlled variable, indicated variable operate to control the process, and their limitations

interaction between multiple control loops, including cascade control

impacts of changing controller settings and the limits within which changes can be made

effective communication techniques

uninterrupt power supplies (UPS) and its applications and use.

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

Non-routine problems

Non-routine problems must be resolved by applying operational knowledge to develop new solutions, either individually or in collaboration with relevant experts, to:

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

Non-routine problems are unexpected problems, or variations of previous problems and include one or more of the following:

loss of power/utilities

variation in feed rate, quality or loss of feed

unstable control of pressure, temperature, level and/or flows

unstable/suboptimal operation

control equipment failure

process plant trips

change in atmospheric conditions (rain, temperature, wind and lightning)

emergency situations

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

Human interface devices

Human interface devices include one or more of the following:

keyboards

track ball/mouse

touch screen

monitor and/or

standalone controllers

Alarms or abnormal conditions

Alarms or other abnormal conditions include the following:

emergency, including emergency shut down

partial or complete controller failure

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 all other conditions experienced on the plant (i.e. from any condition to any condition experienced on the plant)

Operate

Operate is to monitor, adjust/change the plant item/unit/system to meet specifications, by the following:

using the process control system in the control room

This competency does not require operation other than through the control panel.

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