Elements and Performance Criteria

Context
This unit of competency includes all such items of equipment and unit operations, which form part of the production/processing system.

For your local control system this may include (select relevant items):
programmable logic controllers (PLCs)
hard wired control and alarm panels
analogue control systems
personal computers
printers
fire and gas detection/protection systems
emergency shutdown systems
communications systems.

Typical problems for your plant may include:
variation/loss of feed
unstable control of pressure, temperature level and flows
control equipment failure
process plant trips
change in atmospheric conditions (rain, temperature, wind, lightning)
emergency situations.

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.

All work to be undertaken within the limits of the issued permit to work - this may include both hot and cold work requirements and may be within a team or individual context.

Assessment context and methods
Assessment for this unit of competency will be on a local control system. 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 timely assessment of parts of this unit of competency (e.g. elements 3 and 5). Simulation should be based on the actual process control system 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.

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
Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate responses. 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.

Resource implications
Assessment will require access to a process control system 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.

Other assessment advice
In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units. Consider co-assessment with appropriate operations competencies for the unit of plant.

In a major hazard facility, it may be appropriate to assess this unit concurrently with:
PMAOHS200 - Participate in workplace safety procedures

Essential knowledge
Competence includes an understanding of underpinning knowledge. Demonstration of competence in this unit must include knowledge of:
all items on a schematic of the controller and describe the function of each
principles of operation and location of the process/production equipment
specific plant process operations
product specifications and tolerances
systems operating parameters
basis of control for the process
emergency shutdown procedures
process specific physics, chemistry and mathematics
process drawings (e.g. PID, PFS, cause and effect)
instrumentation and control systems
effective communication techniques.

Competence also includes the ability to distinguish between causes of problems/alarms/fault indications such as:
instrument failure/malfunction
electrical failure/malfunction
mechanical failure/malfunction
equipment design deficiencies
product parameters (temperature, flows, pressure and levels).

An ability to communicate with other work groups and personnel during the operation and monitoring of this equipment is considered to be an essential element of this unit of competency.