Unit of competency Outline

Date retreived
22/07/2026 7:44 AM AWST

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Operate complex control systems

Operate complex control systems

Unit of competency
National Code
PMAOPS405A
State Code
W8889
TGA Status
Replaced
DTWD Status
Replaced
Current Release Number
1.00
Current Release Date
30/04/2010
State Implementation and Classification
Approved Date
05/09/2013
Field of Education
030717 - Plant And Machine Operations
Original Release Date
05/09/2013
Nominal Hours
80
Description
This unit covers the operation of a complex control panel. These controllers use a large number of control loops and a broad range of control algorithms. The panel will control entire plant areas and multiple products/ process streams. It will typically be located off plant in a control room and will require managing multiple complex tasks.
Notes
Elements and Performance Criteria
1. Use operator interface.
  • 1.1. Use keyboards, track ball and monitor and/or stand alone controllers to access control system/panel
  • 1.2. Monitor the process using the operator interfaces
  • 1.3. Select appropriate controller modes
  • 1.4. Access historical data and information
  • 1.5. Acknowledge messages and alarms
  • 1.6. Access advanced control features as appropriate
2. Access control information.
  • 2.1. Obtain relevant data and information from the control system by applying systems knowledge
  • 2.2. Identify the status of individual pieces of equipment from the control panel and use information to identify potential faults
  • 2.3. Minimise fluctuations and variations in process through the interpretation of existing trends and control schematics
  • 2.4. Determine the overall operating effectiveness of the plant area related to the required targets for the area
  • 2.5. Record process variations/irregularities to procedures.
3. Control process variations and monitor operations.
  • 3.1. Use historical data to assist the identification of problems
  • 3.2. Process available information to identify potential faults
  • 3.3. Undertake required set point/output changes to meet plant area and process requirements
  • 3.4. Adjust production in response to test results and control panel information
  • 3.5. Monitor key process and environmental variables and take appropriate action
  • 3.6. Adjust controller settings in accordance with procedures
  • 3.7. Use advanced control features as appropriate
  • 3.8. Optimise entire plant area in accordance with guidelines
  • 3.9. Undertake calibration operations as appropriate
  • 3.10. Coordinate with stakeholders external to the plant area as appropriate
  • 3.11. Record adjustments and variations to specifications/schedules
  • 3.12. Communicate to appropriate personnel as required.
4. Facilitate planned and unplanned process start-ups and shut-downs.
  • 4.1. Select and apply procedures to planned startup and shutdown processes
  • 4.2. Select and apply procedures to unplanned shutdown processes
  • 4.3. Implement all required emergency responses
  • 4.4. Communicate necessary information to all personnel affected by events
  • 4.5. Log all required information.
5. Respond to alarms or out of specification conditions.
  • 5.1. Identify system(s) affected by the alarm or condition
  • 5.2. Interpret alarms and prioritise actions to be taken
  • 5.3. Respond to the alarm or incident by following procedures
  • 5.4. Deal with any out of specification material in accordance with procedures
  • 5.5. Communicate the problem/solution to appropriate personnel
  • 5.6. Record the information as required
  • 5.7. Provide details of the alarm and action taken to the next shift at change over
  • 5.8. Follow the incident up see that appropriate action has been taken.
6. Control hazards.
  • 6.1. Identify hazards in the production/processing work area
  • 6.2. Assess the risks arising from those hazards
  • 6.3. Implement measures to control risks in line with procedures and duty of care
7. Resolve other problems within scope of responsibility.
  • 7.1. Identify possible problems in equipment, control systems or process
  • 7.2. Determine problems needing action
  • 7.3. Determine possible fault causes
  • 7.4. Rectify problem using appropriate solution within area of responsibility
  • 7.5. Follow initiated items through until final resolution has occurred
  • 7.6. Report problems outside area of responsibility to designated person.
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 italicized 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
This unit of competency includes all such items of equipment and unit operations which form part of the control system. For your control room this may include (select relevant items):
process control systems (eg Distributed Control Systems)
use of multiple control systems
personal computers
printers
fire and gas detection/protection systems
emergency shutdown systems
communications systems.
Typical problems for your plant may include:
operating without advanced control features
loss of power/utilities
analysing failure modes
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.
Alarms or abnormal conditions
Alarms or other abnormal conditions includes:
emergency, including emergency shut down
partial or complete controller failure.
Other problems
Other problems includes:
problem solving control functions
Appropriate action
Appropriate action includes:
determining problems needing action
determining possible fault causes
rectifying problem using appropriate solution within area of responsibility
following through items initiated until final resolution has occurred
reporting problems outside area of responsibility to designated person.
Procedures
Procedures may be written, verbal, computer-based or in some other form. They include:
all work instructions
standard operating procedures
formulas/recipes
batch sheets
temporary instructions
any similar instructions provided for the smooth running of the plant.
For the purposes of this Training Package, 'procedures' also includes good operating practice as may be defined by industry codes of practice (eg Responsible Care) and government regulations.
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, role plays and 3D virtual reality interactive systems. In the case of evacuation training or of training for competencies practiced in life threatening situations, simulation may be used for the bulk of the training.
This unit of competency requires an application of the knowledge contained in the use of the process control system and its integral equipment, to the level needed to maintain control and recognise and resolve problems. This can 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 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.

Context of and specific resources for assessment
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.

Method of assessment
In all plants it may be appropriate to assess this unit concurrently with relevant teamwork, communication and leadership units.

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
AXM86 PMAOPS405 Operate complex control systems Unit of competency