PMA40113 Certificate IV in Process Plant Technology Release 1
PMA40113 Certificate IV in Process Plant Technology Modification History Release 1 - Supersedes PMA40108. New pathway for metalliferous processing/refining included. All other sector pathways remain equivalent. Approved Page 2 of 18
Description The PMA40113 Certificate IV in Process Plant Technology has been developed as a technical qualification for use in the PMA08 Chemical, Hydrocarbons and Refining Training Package. Job roles/employment outcomes The PMA40113 Certificate IV in Process Plant Technology is intended for plant technicians. The technician will typically be involved in solving complex problems which require theoretical knowledge, combined with an understanding of the production process and equipment across the plant. Application This qualification is typically used to develop employees performing a technical role that includes an ability to work independently and conduct technical problem solving according to the needs of the work in the manufactured mineral products industries. Non-technical team leaders, coordinators and supervisors may be better served by a qualification in competitive manufacturing. The MSA41108 Certificate IV in Competitive Manufacturing is available for team leaders at this level where the job requires sophisticated manufacturing practice skills rather than technical skills. People with this qualification may be expected to work in one of the following sectors: fine chemicals heavy chemicals petrochemicals polymer manufacture hydrocarbon extraction hydrocarbon transmission hydrocarbon processing/refining minerals processing/refining metalliferous processing/refining metals smelting/processing other related areas. Training programs for this qualification are suitable to be undertaken as part of a formal training contract with an employer under an Australian Traineeship or Apprenticeship arrangement. Pathways Information Pathways into the qualification This qualification may be accessed by direct entry. Credit may be granted towards this qualification by those who have completed PMA30113 Certificate III in Process Plant Operations, MSA30107 Certificate III in Process Manufacturing, MSA30208 Certificate III in Manufacturing Technology or other relevant qualifications. Credit for this qualification may also include units contained within relevant skill sets. Approved Page 3 of 18
Pathways from the qualification Further training pathways from this qualification include PMA50110 Diploma of Process Plant Technology, MSA51108 Diploma of Competitive Manufacturing, MSA50108 Diploma of Manufacturing Technology or other relevant qualifications, including appropriate vocational graduate qualifications. Additional qualification advice MSA41108 Certificate IV in Competitive Manufacturing is available for team leaders at this level who already possess technical skills and who require additional manufacturing practice skills above those available in this qualification. Licensing/Regulatory Information There are no specific licences that relate to this qualification. However, in some jurisdictions some units of competency in this qualification may have licensing or regulatory requirements. Local regulations should be checked for details. Entry Requirements Not applicable. Approved Page 4 of 18
Employability Skills Summary Employability Skill Industry/enterprise requirements for this qualification include: Communication maintain communication about multiple subjects and with multiple audiences complete incident and other reports communicate technical information update workplace documentation maintain workplace records Teamwork identify and describe own role and role of other assist others identify role lead team teams either formally or on an ad hoc basis resolve conflicts between teams Problem-solving recognise persistent problems or those not definable by direct observation determine problems needing priority action investigate and analyse problems and potential solutions work with technical experts to define problems and develop possible solutions apply appropriate theory base for problem follow through items initiated until final resolution has occurred identify and isolate faults in entire plant use a range of formal problem solving techniques Initiative and enterprise proactive in fine tuning of entire plant seeks out areas requiring improvement anticipate the impact of the process on customers and value chain members Planning and organising prioritise actions to achieve required outcomes for plant plan work requirements for plant plan plant maintenance or shutdowns/turnarounds identify tasks to achieve plant goals allocate tasks monitor completion of allocated tasks develop and adjust schedules Self-management plan own work requirements from plant requirements operate within appropriate time constraints and work standards select and use appropriate techniques identify resource requirements, document and monitor recognise limitations and seek timely advice Approved Page 5 of 18
Learning maintain and develop own competency assist others to develop their required competencies lead improvement procedures/strategies Technology improvements to and fine tuning of entire process start up and shut down planning and coordinating a shut down/start up of plant solving of problems not directly observable monitor product/process quality function and operating principles of unit, system or plant area maintain workplace records Approved Page 6 of 18
Packaging Rules To be awarded the PMA40113 Certificate IV in Process Plant Technology competency must be achieved in twenty six (26) units of competency: five (5) core units of competency twenty one (21) elective units of competency chosen as specified below. Note: Where prerequisite units apply, these must be considered in the total number of units chosen. Core units of competency Unit code MSAENV272B MSAPMOHS110A MSAPMOHS200A MSAPMSUP100A MSAPMSUP102A Unit title Participate in environmentally sustainable work practices Follow emergency response procedures Work safely Apply workplace procedures Communicate in the workplace Elective units of competency Select twenty one (21) units as specified below: A minimum of one (1) from Group A The remainder may be chosen from Groups A, B and C (with a maximum of eighteen (18) from Group C) to bring the total number of electives to twenty one (21). Note that up to five (5) units can be chosen from other qualifications in this Training Package, other endorsed Training Packages and accredited courses, as specified in Groups B and C. Group A Specialist electives Unit code Unit title Prerequisites Approved Page 7 of 18
MSAPMOPS400A Optimise process/plant area * MSAPMOPS401A Trial new process product PMAOPS402A Respond to abnormal process situations * PMAOPS405A PMAOPS410B PMAOPS411B PMAOPS433A PMAOPS434A PMAOPS450B PMAOPS460A Operate complex control systems Monitor remote production facilities Manage plant shutdown and restart Manage wells and gathering systems Commission wells and gathering systems Solve colour problems Monitor and operate tailings management facilities One (1) unit may be chosen from Group A in PMA50110 Diploma of Process Plant Technology Group B Unit code Unit title Prerequisites MSS403011A MSS403013A MSS403002A MSS403030A MSS403040A MSS403041A MSS403051A Lead a competitive manufacturing team Lead team culture improvement Ensure process improvements are sustained Improve cost factors in work practices Facilitate and improve implementation of 5S Facilitate breakthough improvements Mistake proof an operational process MSS404051A Undertake process capability improvements * Approved Page 8 of 18
MSS405052A MSS404060A MSS404081A MSS404082A MSAENV472B MSAPMOHS400A MSAPMOHS401A MSAPMOPS404A MSAPMOPS405A MSAPMOPS406A Apply statistics to operational processes Facilitate the use of planning software systems in a work area or team Undertake proactive maintenance analyses Assist in implementing a proactive maintenance strategy Implement and monitor environmentally sustainable work practices Contribute to workplace OHS management system Assess risk Co-ordinate maintenance Identify problems in fluid power system Identify problems in electronic control systems * * MSAPMPER400A Coordinate permit process * MSAPMSUP400A MSL954001A PMAOHS420B Develop and monitor quality systems Obtain representative samples in accordance with a sampling plan Develop first aid procedures and manage resources PMAOMIR305A Operate panel during an emergency * PMAOMIR407B PMAOMIR418B PMAOMIR424B PMAOMIR430B PMAOMIR444B Audit incident preparedness and established response system Coordinate incident response Develop and maintain community relationships Conduct and assess incident exercises Develop incident containment tactics Approved Page 9 of 18
PMAOMIR449B PMASUP410B PMASUP420B PMASUP432B PMASUP440B PMASUP441C PMASUP444A Monitor legal compliance obligations during incidents Develop plant documentation Minimise environmental impact of process Coordinate pipeline projects Commission/recommission plant Decommission plant Plan plant preparation and isolation PMASUP445A Participate in HAZOP studies * TAEASS401B TAEASS402B TAEASS403B Plan assessment activities and processes Assess competence Participate in assessment validation Up to one (1) relevant unit may be chosen from this Training Package, other endorsed Training Packages and accredited courses, where that unit is available at Certificate IV or Diploma. Group C Unit code Unit title Prerequisites FDFPH1001A FDFPH2001A FDFPHGMP3A MEM05012C MEM07033B Follow work procedures to maintain Good Manufacturing Practice Apply Good Manufacturing Practice procedures Monitor the implementation of Good Manufacturing Practice procedures Perform routine manual metal arc welding Operate and monitor basic boiler Approved Page 10 of 18
MEM07034A Operate and monitor intermediate class boiler * MEM09002B Interpret technical drawing MEM09003B Prepare basic engineering drawing * MEM11011B MEM16005A MEM18011C MEM40001B MSS402002A MSS402030A MSS402031A MSS402040A MSS402050A MSS402051A MSS402060A MSS402080A MSS402081A MSAPMOHS100A MSAPMOHS205A MSAPMOHS210B MSAPMOHS212A MSAPMOHS216A MSAPMOHS217A MSAPMOHS220A Undertake manual handling Operate as a team member to conduct manufacturing, engineering or related activities Shutdown and isolate machines/equipment Operate melting furnaces Sustain process improvements Apply cost factors to work practices Interpret product costs in terms of customer requirements Apply 5S procedures Monitor process capability Apply quality standards Use planning software systems in operations Undertake root cause analysis Contribute to the application of a proactive maintenance strategy Follow OHS procedures Control minor incidents Undertake first response to non-fire incidents Undertake first response to fire incidents Operate breathing apparatus Gas test atmospheres Provide initial first aid response Approved Page 11 of 18
MSAPMOHS300A MSAPMOPS100A MSAPMOPS102A MSAPMOPS200A MSAPMOPS212A MSAPMPER200C MSAPMPER201A MSAPMPER202A MSAPMPER205C Facilitate the implementation of OHS for a work group Use equipment Perform tasks to support production Operate equipment Use enterprise computers or data systems Work in accordance with an issued permit Monitor and control work permits Observe permit work Enter confined space MSAPMPER300C Issue work permits * MSAPMSUP101A MSAPMSUP106A MSAPMSUP172A MSAPMSUP200A MSAPMSUP201A MSAPMSUP204A MSAPMSUP205A MSAPMSUP210A MSAPMSUP240A MSAPMSUP280A MSAPMSUP291A MSAPMSUP292A MSAPMSUP300A MSAPMSUP301A Clean workplace or equipment Work in a team Identify and minimise environmental hazards Achieve work outcomes Receive or despatch goods Pack products or materials Transfer loads Process and record information Undertake minor maintenance Manage conflict at work Participate in continuous improvement Sample and test materials and product Identify and implement opportunities to maximise production efficiencies Apply HACCP to the workplace * Approved Page 12 of 18
MSAPMSUP303A MSAPMSUP309A MSAPMSUP310A MSAPMSUP330A MSAPMSUP382A MSAPMSUP383A MSAPMSUP390A MSL952001A MSL973001A NWP357B PMAOHS211B PMAOHS213B PMAOHS214B PMAOHS215B PMAOHS221B PMAOHS310B PMAOHS311B PMAOHS312B PMAOHS320C PMAOHS321B PMAOMIR210B PMAOMIR301B PMAOMIR302B Identify equipment faults Maintain and organise workplace records Contribute to development of plant documentation Develop and adjust a production schedule Provide coaching/mentoring in the workplace Facilitate a team Use structured problem solving tools Collect routine site samples Perform basic tests Monitor, operate and control reverse osmosis and nano-filtration processes Prepare equipment for emergency response Undertake fire control and emergency rescue Undertake helicopter safety and escape Apply offshore facility abandonment and sea survival procedures Maintain first aid supplies and records Investigate incidents Lead emergency teams Command the operation of survival craft Provide advanced first aid response Provide first aid response in remote and/or isolated area Control evacuation to muster point Undertake initial rescue Respond to a helideck incident Approved Page 13 of 18
PMAOMIR317B PMAOMIR320B PMAOMIR321B PMAOMIR346B PMAOPS101C PMAOPS105C PMAOPS201B PMAOPS202B PMAOPS203B PMAOPS204B PMAOPS205B PMAOPS208B PMAOPS210B PMAOPS211B PMAOPS213B PMAOPS216B PMAOPS217B PMAOPS220B PMAOPS221B PMAOPS222B PMAOPS223B PMAOPS224B PMAOPS230B Facilitate search and rescue operations Manage incident response information Manage communication systems during an incident Assess and secure an incident site Read dials and indicators Select and prepare materials Operate fluid flow equipment Operate fluid mixing equipment Handle goods Use utilities and services Operate heat exchangers Operate chemical separation equipment Operate particulates handling equipment Operate manufacturing extruders Package product/material Operate local control system Operate wet milling equipment Monitor chemical reactions in the process Operate and monitor prime movers Operate and monitor pumping systems and equipment Operate and monitor valve systems Provide fluids for utilities and support Monitor, operate and maintain pipeline stations and equipment * Approved Page 14 of 18
PMAOPS231B PMAOPS232B PMAOPS233A PMAOPS234A PMAOPS240B PMAOPS241A PMAOPS242A PMAOPS246A PMAOPS247A PMAOPS260A PMAOPS261A PMAOPS262A PMAOPS263A PMAOPS264A PMAOPS265A PMAOPS280B PMAOPS290B PMAOPS300B Control gas odourisation Produce product by filtration Monitor wells and gathering systems Monitor and operate low pressure compressors Store liquids in bulk Operate Joule-Thomson effect device Moor ships for transfer of bulk processed particulates or fluids Operate separation equipment Operate powered separation equipment Conduct screening operations Operate bulk solids loading equipment Operate digestion equipment Operate leaching equipment Operate solvent extraction equipment Operate magnetic/electrical separation equipment Interpret process plant schematics Operate a biotreater Operate a production unit PMAOPS301B Produce products by distillation * PMAOPS302B PMAOPS303B PMAOPS304B PMAOPS305B Operate reactors and reaction equipment Operate furnaces to induce reaction Operate and monitor compressor systems and equipment Operate process control systems * Approved Page 15 of 18
PMAOPS307B Transfer bulk fluids into/out of storage facility * PMAOPS308B PMAOPS309B PMAOPS312B PMAOPS319A PMAOPS320B PMAOPS321B PMAOPS323A PMAOPS324A PMAOPS325B PMAOPS326B PMAOPS327B PMAOPS329B PMAOPS330B PMAOPS333A PMAOPS335A PMAOPS340B PMAOPS350B PMAOPS360A PMAOPS361A PMAOPS362A PMAOPS364A PMAOPS365A Organise storage and logistics of general materials Operate particulates handling/ storage equipment Undertake ship loading/unloading operations Adjust batch Conduct artificial lift Undertake well management Operate and monitor heating furnace Operate a gas turbine Generate electrical power Produce product using gas absorption Produce product using fixed bed dehydration Produce product using liquid extraction Communicate pipeline control centre operations Operate wells and gathering systems Conduct pipeline pigging Operate cryogenic processes Match and adjust colour Operate a metalliferous kiln/furnace Operate a smelting furnace Operate a blast furnace Operate an electrochemical process Operate pelletising equipment Approved Page 16 of 18
PMAOPS366A PMAOPS390B PMASMELT260B PMASMELT261B PMASMELT262B PMASMELT263B PMASMELT264B PMASMELT265B PMASMELT266B PMASMELT267B PMASMELT268B PMASMELT269A PMASMELT270A PMASUP236B PMASUP237B PMASUP241B PMASUP242B PMASUP243B PMASUP244A PMASUP305A PMASUP311A PMASUP341B Operate sintering equipment Operate a biochemical process Form carbon anodes Bake carbon anodes Clean and strip anode rods Spray carbon anodes Start up reduction cells Operate reduction cells Deliver molten metal Cast aluminium ingots Vertical direct casting Operate cell tending equipment Supply product from reduction cells Operate vehicles in the field Undertake crane, dogging and load transfer operations Maintain pipeline easements Monitor pipeline civil works Monitor and maintain pipeline coatings Prepare and isolate plant Operate offshore cranes Operate communications hub Monitor and maintain instrument and control systems * PMASUP342B Monitor and maintain electrical systems * PMASUP343B Monitor and maintain cathodic protection Approved Page 17 of 18
systems PMASUP344B PMASUP345A PMASUP346A PMASUP347A PMC552002C PMC552003C PMC552008B PMC562070B PSPGOV308B RIIOHS204A RIIRIS201B TAEASS301B TAEDEL301A TLID2010A UEPOPS319B UEPOPS340B Monitor and control repairs and modifications on operational pipe Monitor vibration Control corrosion Undertake corrosion inspection in a petrochemical environment Operate equipment to blend/mix materials Operate grinding equipment Operate crushing equipment Move materials Work effectively with diversity Work safely at heights Conduct local risk control Contribute to assessment Provide work skill instruction Operate a forklift Operate and monitor gas production plant Operate and monitor a steam turbine Up to four (4) relevant units may be chosen from this Training Package, other endorsed Training Packages and accredited courses where those units are available at Certificates III and IV. Custom Content Section Not applicable. Approved Page 18 of 18