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Evidence Guide: PMAOPS601 - Debottleneck plant

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

 

PMAOPS601 - Debottleneck plant

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

Identify rate limiting step/process

  1. Determine throughput of plant/area
  2. Determine capacity of units within plant/area based on design and/or performance data
  3. Identify which units is operating at capacity/is the bottleneck
Determine throughput of plant/area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine capacity of units within plant/area based on design and/or performance data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify which units is operating at capacity/is the bottleneck

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Investigate bottleneck

  1. Analyse the science of what is occurring in the bottleneck unit
  2. Analyse the engineering/design specification of the bottleneck unit
  3. Determine the root cause of the capacity limitation of the bottleneck unit
  4. Investigate methods of increasing the capacity of the bottleneck unit
  5. List solutions to the bottleneck
Analyse the science of what is occurring in the bottleneck unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Analyse the engineering/design specification of the bottleneck unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine the root cause of the capacity limitation of the bottleneck unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Investigate methods of increasing the capacity of the bottleneck unit

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

List solutions to the bottleneck

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Select technically best solution

  1. Investigate impact of solutions on the other units of the plant/area
  2. Identify any 'knock on' effects of solution
  3. Determine process/quality benefits and costs of solutions
  4. Determine economic benefits and costs of solutions
  5. Short list and rank the best solutions
Investigate impact of solutions on the other units of the plant/area

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Identify any 'knock on' effects of solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine process/quality benefits and costs of solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Determine economic benefits and costs of solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Short list and rank the best solutions

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Compare hazard profile of possible solutions

  1. Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the solutions according to company procedures
  2. Ensure that all stakeholders are represented on the hazard analysis team
  3. Brief the hazard analysis team on the problem and solution alternatives under evaluation
  4. Eliminate alternatives which do not meet hazard requirements
  5. Rank remaining competing items by safety performance
Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the solutions according to company procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure that all stakeholders are represented on the hazard analysis team

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Brief the hazard analysis team on the problem and solution alternatives under evaluation

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Eliminate alternatives which do not meet hazard requirements

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Rank remaining competing items by safety performance

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make final choice of solution

  1. Seek further information, where necessary, to allow a rational selection to be made
  2. Choose the modification which meets all required minimum standards and will provide the best solution
  3. Verify choice in discussion with production and engineering managers and other key stakeholders
Seek further information, where necessary, to allow a rational selection to be made

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Choose the modification which meets all required minimum standards and will provide the best solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Verify choice in discussion with production and engineering managers and other key stakeholders

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Check solution

  1. Initiate and monitor the implementation of the solution
  2. Ensure all checks and acceptances are done to procedures
  3. Conduct trials/test runs as required
  4. Collect and analyse data
Initiate and monitor the implementation of the solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure all checks and acceptances are done to procedures

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Conduct trials/test runs as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Collect and analyse data

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete modification

  1. Evaluate performance of solution
  2. Make adjustments as required
  3. Ensure plant procedures and training material updated
  4. Ensure plant drawings and engineering specifications are updated
  5. Complete all other required paperwork
Evaluate performance of solution

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Make adjustments as required

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure plant procedures and training material updated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Ensure plant drawings and engineering specifications are updated

Completed
Date:

Teacher:		 Evidence:

 

 

 

 

 

 

 

Complete all other required paperwork

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

Identify rate limiting step/process

1.1

Determine throughput of plant/area

1.2

Determine capacity of units within plant/area based on design and/or performance data

1.3

Identify which units is operating at capacity/is the bottleneck

2

Investigate bottleneck

2.1

Analyse the science of what is occurring in the bottleneck unit

2.2

Analyse the engineering/design specification of the bottleneck unit

2.3

Determine the root cause of the capacity limitation of the bottleneck unit

2.4

Investigate methods of increasing the capacity of the bottleneck unit

2.5

List solutions to the bottleneck

3

Select technically best solution

3.1

Investigate impact of solutions on the other units of the plant/area

3.2

Identify any 'knock on' effects of solution

3.3

Determine process/quality benefits and costs of solutions

3.4

Determine economic benefits and costs of solutions

3.5

Short list and rank the best solutions

4

Compare hazard profile of possible solutions

4.1

Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the solutions according to company procedures

4.2

Ensure that all stakeholders are represented on the hazard analysis team

4.3

Brief the hazard analysis team on the problem and solution alternatives under evaluation

4.4

Eliminate alternatives which do not meet hazard requirements

4.5

Rank remaining competing items by safety performance

5

Make final choice of solution

5.1

Seek further information, where necessary, to allow a rational selection to be made

5.2

Choose the modification which meets all required minimum standards and will provide the best solution

5.3

Verify choice in discussion with production and engineering managers and other key stakeholders

6

Check solution

6.1

Initiate and monitor the implementation of the solution

6.2

Ensure all checks and acceptances are done to procedures

6.3

Conduct trials/test runs as required

6.4

Collect and analyse data

7

Complete modification

7.1

Evaluate performance of solution

7.2

Make adjustments as required

7.3

Ensure plant procedures and training material updated

7.4

Ensure plant drawings and engineering specifications are updated

7.5

Complete all other required paperwork

Required Skills and Knowledge

Elements describe the essential outcomes.

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

1

Identify rate limiting step/process

1.1

Determine throughput of plant/area

1.2

Determine capacity of units within plant/area based on design and/or performance data

1.3

Identify which units is operating at capacity/is the bottleneck

2

Investigate bottleneck

2.1

Analyse the science of what is occurring in the bottleneck unit

2.2

Analyse the engineering/design specification of the bottleneck unit

2.3

Determine the root cause of the capacity limitation of the bottleneck unit

2.4

Investigate methods of increasing the capacity of the bottleneck unit

2.5

List solutions to the bottleneck

3

Select technically best solution

3.1

Investigate impact of solutions on the other units of the plant/area

3.2

Identify any 'knock on' effects of solution

3.3

Determine process/quality benefits and costs of solutions

3.4

Determine economic benefits and costs of solutions

3.5

Short list and rank the best solutions

4

Compare hazard profile of possible solutions

4.1

Organise a hazard analysis (e.g. hazard and operability study (HAZOP)) for the solutions according to company procedures

4.2

Ensure that all stakeholders are represented on the hazard analysis team

4.3

Brief the hazard analysis team on the problem and solution alternatives under evaluation

4.4

Eliminate alternatives which do not meet hazard requirements

4.5

Rank remaining competing items by safety performance

5

Make final choice of solution

5.1

Seek further information, where necessary, to allow a rational selection to be made

5.2

Choose the modification which meets all required minimum standards and will provide the best solution

5.3

Verify choice in discussion with production and engineering managers and other key stakeholders

6

Check solution

6.1

Initiate and monitor the implementation of the solution

6.2

Ensure all checks and acceptances are done to procedures

6.3

Conduct trials/test runs as required

6.4

Collect and analyse data

7

Complete modification

7.1

Evaluate performance of solution

7.2

Make adjustments as required

7.3

Ensure plant procedures and training material updated

7.4

Ensure plant drawings and engineering specifications are updated

7.5

Complete all other required paperwork

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:

determine options for debottlenecking to address identified needs

determine agreed technical requirements, operations requirements, timelines, cost and other requirements for modifications

evaluate types of modification and classes of equipment against specifications, hazard and operability study (HAZOP), economic performance and legislative requirements to select best solution

ensure training, procedures, plant drawings and specifications are updated to reflect modifications.

Evidence must be provided that demonstrates knowledge of:

the operations of the plant and each major unit in it

the principles of operation of the equipment being investigated to the extent required to interpret technical specifications in a meaningful manner

the basics of plant economics and whole of life costing

hazard analysis principles

typical hazards with the type of equipment being investigated

work health and safety (WHS) legislative requirements related to plant, including registration and documentation requirements related to modification of registered plant

problem isolation techniques

problem analysis techniques

systems operating parameters, integrity limits

process-specific science (physics, chemistry and biochemistry)

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

flow, pressure

equipment failures

plant services (steam, condensate and cooling water)

flammabilityand explosivity

hazardous products and materials

other hazards that might arise

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.