- MSAPMSUP240A - Undertake minor maintenance
MSAPMSUP240A
Undertake minor maintenance
Application
Application of this unit
In a typical scenario a plant operator does minor maintenance activities on the plant and equipment being operated. For instance the pressure drop across a filter unit may be high, indicating the filter cartridge needs changing. The operator takes the filter unit out of operation, cleans the unit, uses the correct spanner to open the lid, installs a fresh cartridge, closes the unit using the spanner again, then cleans up the area and disposes of the spent cartridge. Typically this sort of maintenance will be done on the plant and will not require workshop type facilities.
The operator will:
be aware of and contribute to a safe working environment
identify and check equipment for faults
perform basic maintenance to procedures
complete logs and reports.
Prerequisites
Prerequisites
This unit has no prerequisites.
Elements and Performance Criteria
ELEMENT ELEMENT | PERFORMANCE CRITERIA Performance Criteria describe the required performance needed to demonstrate achievement of the Element. Assessment of performance is to be consistent with the Evidence Guide. |
1. Identify maintenance requirements. | 1.1 Identify equipment variations/irregularities using observed data and plant records. 1.2 Assess the urgency/priority of the situation. 1.3 Identify appropriate corrective action. 1.4 Identify correct tools and materials. 1.5 Assess the impact of the maintenance activity and communicate to appropriate personnel. 1.6 Identify hazards and risk controls. 1.7 Identify work permit requirements. |
2. Prepare for maintenance activity. | 2.1 Ensure equipment is turned off and isolated as required. 2.2 Clear the area of obstructions and hazardous materials. 2.3 Obtain appropriate tools, parts, materials and procedures. 2.4 Obtain the appropriate work permits and adhere to the requirements. 2.5 Communicate the impending maintenance activity to the appropriate personnel. |
3. Perform maintenance activity. | 3.1 Access all relevant information. 3.2 Undertake maintenance activity according to procedures. 3.3 Use tools and maintenance techniques correctly. 3.4 Restore equipment to normal working condition. 3.5 Leave the work area in a clean and safe condition. 3.6 Ensure permits are signed off as appropriate. |
4. Test equipment. | 4.1 Test equipment according to procedures. 4.2 Return equipment to service. 4.3 Ensure equipment meets normal operating requirements. |
5 Record maintenance activity. | 5.1 Complete maintenance logs/plant history records. 5.2 Report maintenance activity to relevant personnel. 5.3 Identify and report outstanding maintenance requirements to relevant personnel. |
Required Skills
This describes the essential skills and knowledge and their level required for this unit.
Knowledge and understanding of equipment operation and maintenance practices sufficient to recognise fault and no-fault conditions in standard and non-standard situations and then determine appropriate action which is consistent with operational guidelines is required.
Knowledge of organisation procedures and relevant regulatory requirements along with the ability to implement them within appropriate time constraints and work standards.
Application of the knowledge of managing risks using the hierarchy of controls applied to the process. Application of approved hazard control, safety procedures, use of PPE in relation to handling materials, equipment operation and clean up.
Knowledge as a basis for solving maintenance problems, including:
principles of operation of the equipment to be maintained
function and troubleshooting of major internal components and their problems
appropriate testing procedures and use of equipment for a range of equipment faults
typical causes of equipment failures and the service conditions which may increase maintenance
types and nature of maintenance (preventative, predictive, corrective) uses, benefits and limitations
urgency and timeliness factors in maintenance
maintenance planning/scheduling/records systems
identification of tools, materials and spare parts
basic techniques for using and handling tools
physical measurement, alignment and clearance principles.
Competence also includes the ability to:
plan own work, including predicting consequences and identifying improvements
identify factors which may affect product quality or production output and appropriate remedies
identify when the operator is able to rectify faults and when assistance is required.
Language, literacy and numeracy requirements
This unit requires the ability to read and interpret typical equipment specifications schematics and diagrams.
Writing is required to the level of completing workplace forms and production reports.
Basic numeracy is required, to interpret plant data and maintenance schedules.
Evidence Required
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 this Training Package.
Overview of assessment
A holistic approach should be taken to the assessment.
Assessors must be satisfied that the person can consistently perform the unit as a whole, as defined by the Elements, Performance Criteria and skills and knowledge.
Where the completion of this unit requires working under a permit/clearance, then competency must also be established in PMAPER200C Work in accordance with an issued permit, or other appropriate unit.
Critical aspects for assessment and evidence required to demonstrate competency in this unit
It is essential that competence is demonstrated in the knowledge and skills defined in this unit. These may include the ability to:
understand the procedures and know the importance of critical operational systems
recognise potential situations requiring action and then implement appropriate action.
Consistent performance should be demonstrated. For example, look to see that:
early warning signs of equipment in need of attention/with potential problems are recognised
appropriate equipment tests are undertaken and analysed appropriately
proposals for equipment repair are based upon the most appropriate and cost effective method to return equipment to full performance in a timely manner
maintenance activities are completed safely and to procedures.
Assessment method and context
Assessment will occur on industrial equipment and will be undertaken in a work-like environment.
Competence in this unit may be assessed:
on a processing plant, allowing for operation under all normal and a range of abnormal conditions
in a situation allowing the generation of evidence of the ability to respond to problems
by using a suitable simulation and/or a range of case studies/scenarios
through a combination of these techniques.
In all cases it is expected that practical assessment will be combined with targeted questioning to assess the underpinning knowledge and theoretical assessment will be combined with appropriate practical/simulation or similar assessment. Assessors need to be aware of any cultural issues that may affect responses to questions.
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.
Specific resources for assessment
This section should be read in conjunction with the Range Statement for this unit of competency. Resources required include suitable access to an operating plant or equipment that allows for appropriate and realistic simulation. A bank of case studies/scenarios and questions will also be required to the extent that they form part of the assessment method. Questioning may take place either in the workplace, or in an adjacent, quiet facility such as an office or lunchroom. No other special resources are required.
Access must be provided to appropriate learning and/or assessment support when required. Where applicable, physical resources should include equipment modified for people with disabilities.
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. Add any essential operating conditions that may be present with training and assessment depending on the work situation, needs of the candidate, accessibility of the item, and local industry and regional contexts.
Where reference is made to industry codes of practice, and/or Australian/international standards, the latest version must be used.
Context
This competency applies to all work environments and sectors within the industry. It does not include maintenance that would require trade level skills. It is not intended that this competency would cover maintenance that is carried out in a workshop.
Procedures
All operations are performed in accordance with procedures.
Procedures mean all relevant workplace procedures, work instructions, temporary instructions, standard operating procedures, plant description manuals, manufacturer instructions, specifications, service manuals, machine circuit diagrams for hydraulic/pneumatic and electrical/electronic circuits and relevant industry and government codes and standards.
Maintenance activities
This competency unit includes minor maintenance such as the following:
operational maintenance (eg connection-disconnection of hoses, greasing, lubrication and lubricant systems, adjusting sealing glands, cleaning and changing filters, 'nipping up' flanges)
general cleaning
removal and replacement (eg gland packing, changing blades or cutters, replacing gaskets, replacing /maintaining seals, changing filter elements, servicing strainers).
Tools and equipment
This competency includes use of equipment and tools such as:
hand tools
specialised tools
measuring and aligning equipment.
Hazards
Typical hazards include:
rotating and moving machinery
process materials, solids, liquids and gases under pressure or flowing
hot surfaces or materials
temporary connections or by-passes
electrical, hydraulic or pneumatic energy sources
out of specification operation.
Problems
Respond to/rectify 'non-routine problems' means 'apply known solutions to a variety of predictable problems'. Typical process and product problems may include:
out-of-specification product or variations
response of equipment to materials variations
equipment in need of maintenance.
Variables
Key variables to be monitored include:
equipment performance (eg speed, output, variations)
equipment component performance
sequences and timing of operations
materials changes (desired and not desired).
Data and Records
Typical information sources, observed data and plant records may include:
plant data
log sheets
operational and performance reports
physical aspects such as noise, smell, feel and pressure condition monitoring information
planned maintenance schedules
procedures
manufacturer specifications, instructions, service manuals and other information.
Sectors
Not applicable.
Employability Skills
This unit contains employability skills.
Licensing Information
Not applicable.