Unit of competency Outline
Date retreived
22/07/2026 1:32 AM AWST
22/07/2026 1:32 AM AWST
Whilst all efforts are made to provide accurate and timely information from the relevant source/documentation, please be aware that the information supplied may not be the most current version. The accuracy of the detail has not been confirmed by the Department and therefore should not be relied upon without first confirming the contents.
Debottleneck plant
Debottleneck plant
Unit of competency
National Code
PMAOPS601A
PMAOPS601A
State Code
W8903
W8903
TGA Status
Replaced
Replaced
DTWD Status
Replaced
Replaced
State Implementation and Classification
Approved Date
10/06/2011
Field of Education
030101 - Manufacturing Engineering
Original Release Date
10/06/2011
Nominal Hours
60
Description
In a typical scenario, it is desired to increase the throughput of a plant. A study is undertaken to identify the rate limiting step/process/plant unit (bottleneck) and then changes are made to plant or process conditions to increase the throughput of this unit. The making of plant modifications is not part of this unit (see PMAOPS600C Modify plant).This competency may require the technician to work with technical experts to complete the debottlenecking project. Typically this unit would be applied to either a small plant or a section/area of a larger plant.
Notes
Elements and Performance Criteria
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 unit(s) is operating at capacity/is the bottleneck
2. Investigate bottleneck.
- 2.1. Analyse the science of what is occurring in the bottle neck unit
- 2.2. Analyse the engineering/design specification of the bottle neck 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 bottle neck unit
- 2.5. List solutions to the bottle neck.
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 (eg 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 solution 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
- 5.4. Obtain necessary approvals/authorisations
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.
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 if 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.
Context
The need for the modification may arise from a continuous improvement project, as a result of an analysis of plant performance or from any other source.
Required minimum standards include:
OHS legislative requirements related to plant
industry and enterprise OHS standards
enterprise standards related to maintenance
output requirements
economic performance
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.
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 if 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.
Context
The need for the modification may arise from a continuous improvement project, as a result of an analysis of plant performance or from any other source.
Required minimum standards include:
OHS legislative requirements related to plant
industry and enterprise OHS standards
enterprise standards related to maintenance
output requirements
economic performance
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.
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 and role plays.
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 for assessment and evidence required to demonstrate competency in this unit
Competence must be demonstrated in the ability to specify the requirements and then select the best solution to meet the necessary and desirable requirements.
In particular look to see that:
safety, technical and economic aspects are all considered
the decision made can be justified on those criteria
all key stakeholders are kept well informed and agree with the decisions
the modification, and particularly its timelines, are a good fit for the overall plant requirements
obvious problems in related plant areas are recognised and an appropriate contribution made to their solution.
This will typically be assessed by a modification project on an operating plant. One complex project, or a number of simple projects, are required to demonstrate competence.
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.
It may be appropriate to assess this unit concurrently with units which deal with:
plant documentation
assessing risk.
energy and mass balances
plant modifications
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.
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 and role plays.
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 for assessment and evidence required to demonstrate competency in this unit
Competence must be demonstrated in the ability to specify the requirements and then select the best solution to meet the necessary and desirable requirements.
In particular look to see that:
safety, technical and economic aspects are all considered
the decision made can be justified on those criteria
all key stakeholders are kept well informed and agree with the decisions
the modification, and particularly its timelines, are a good fit for the overall plant requirements
obvious problems in related plant areas are recognised and an appropriate contribution made to their solution.
This will typically be assessed by a modification project on an operating plant. One complex project, or a number of simple projects, are required to demonstrate competence.
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.
It may be appropriate to assess this unit concurrently with units which deal with:
plant documentation
assessing risk.
energy and mass balances
plant modifications
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.
Replaced By
| State Code | National Code | Title | Type |
|---|---|---|---|
| AXM67 | PMAOPS601 | Debottleneck plant | Unit of competency |
| State Code | National Code | Title | Type |
|---|---|---|---|
| W752 | PMC60110 | Advanced Diploma of Manufactured Mineral Products | Qualification |
| W519 | PMA60108 | Advanced Diploma of Process Plant Technology | Qualification |