In a typical scenario a complex and integrated plant needs to be shut down for planned maintenance, integrity inspections or process activities. This may be an entire plant/site, or a significant plant/area within that. This requires the coordination of a number of work groups and resources to ensure safe and efficient preparing of equipment for handover to maintenance, contractor or process for shut down activities.

This competency does not cover the technician actually shutting down the plant (see PMAOPS411B Manage Plant shutdown and restart) or with the shutdown planning from initial scoping (see PMAOPS521C Plan Plant shutdown)

Key aspects of the competency include:

coordinating shutdown sequence to ensure all process shutdown activities completed to schedule

communicating shutdown and equipment preparation activities to all stakeholders in a timely manner

a comprehensive knowledge of plant shutdown events and their impact on upstream and down stream interfaces

efficient identification and utilisation of available resources

effective coordination of a number of teams performing a number activities simultaneously

analyse/problem solve and develop contingencies plans to safely manage

identify and coordinate pre shutdown preparation requirements

ELEMENT

PERFORMANCE CRITERIA

1. Identify shutdown work scope

1.1. Analyse relevant information for activities intended for the shutdown

1.2. Complete a list of all activities intended for shutdown

1.3. Prioritise list and identify all essential work

1.4. Identify conflicts between proposed activities

2. Plan and schedule resources

2.1. Identify each individual task in the shutdown process

2.2. Determine resources required for each task and assign appropriate owner

2.3. Determine prerequisite tasks prior to shutting down process

2.4. Ensure hazards are identified and controls are in place

2.5. Ensure all safety and testing equipment is calibrated and on site prior to shutdown commencing

2.6. Compile a schedule to track shutdown and equipment preparation sequence

3. Co-ordinate plant/ equipment shutdown sequence

3.1. Prepare/review shutdown documentation

3.2. Coordinate plant shutdown as per procedures

3.3. Track plant shutdown progress.

3.4. Coordinate execution of critical function test during shut down phase

3.5. Coordinate equipment preparation

3.6. Validate equipment is safe to handover to appropriate work party.

4. Handover plant/ equipment to relevant work party

4.1. Handover plant and equipment to relevant work group per site protocol

4.2. Perform safety audits during shutdown work

4.3. Record/report HSE non conformance

4.4. Communicate as and when required

4.5. Monitor shutdown work against critical path

4.6. Monitor resource usage and take appropriate action

4.7. Identify barriers to achieving shutdown critical path and negotiate solution.

5. Communicate with all relevant stakeholders

5.1. Communicate shutdown plan/schedule to operations team

5.2. Attend and contribute to regular shutdown progress meetings

5.3. Record and report daily shutdown activities.

5.4. Ensure all authorisations required for tasks have been obtained

5.5. Identify, communicate and mange HSE issues arising during execution of shut down activities

5.6. Contribute to post shutdown review.

6. Return plant to service

6.1. Confirm that all scheduled work on equipment is complete before hand back is accepted

6.2. Ensure equipment hand back documentation complete per site protocol

6.3. Coordinate pre-start equipment integrity checks

6.4. Coordinate and validate plant de-isolation and preparation for service

6.5. Ensure appropriate plant start up authority is obtained

6.6. Coordinate start up critical function tests as required

6.7. Coordinate and record plant start up progress

This describes the essential skills and knowledge and their level, required for this unit.

Required skills

Competence also includes the ability to:

interpret shutdown schedule/planning tools (eg Gant chart, MS project, Primavera)

identify and manage HSE risks using appropriate tools (eg HAZOPS, JHA)

coordinate a number of tasks simultaneously

apply legislative requirements and company policies and procedure

solve problems

monitor and coordinate resource requirements

communicate

write or review and apply documentation

lead teams

undertake structured analysis of shutdown activities before and during the shutdown

Required knowledge

Competence in this unit includes the following knowledge:

detailed principles of operation of the plant involved in the shut down

overview of the principles of operation of and any upstream and downstream processes

HSE impact of any shutdown

plant/equipment/processes impacted by the shutdown

safe working practices related to the type of plant and equipment being shut down and worked on

interpretation of work scope and identification of conflicts

analysis of planned sequences of events to identify possible conflicts

organisation computer applications (eg those used to track/record shutdown schedule

interpret complicated P&IDs, PFDs, etc.

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.

Typically this unit will be assessed by a shutdown planning project. As shutdowns may not occur with sufficient frequency or planning to allow for assessment of all elements, performance criteria, required skills and knowledge, simulation may be required to assess some aspects of this competency.

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 undertake a structured analysis of the activities to be completed during the shutdown and then undertaking the coordination in a systematic manner.

Consistent performance should be demonstrated, in the following:

in-depth analysis of all proposed shut down activities to eliminate conflicts and minimise the shutdown critical path

resource management maximises pre shutdown preparations to minimise interruptions to the critical path

coordinate shutdown team to ensure safe and efficient plant shutdown and preparation per procedures without incident.

coordinate track shutdown activities to ensure critical path milestones are reached per plan

contingencies are developed to overcome unforseen barriers to plan

record and report all aspects of shutdown activities to stakeholders per enterprise protocol

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

Typically this unit will be assessed by performing a shutdown coordination project. Assessment should be evidence based through direct observation and the compilation of an evidence portfolio to support the Elements, Performance Criteria, Skills and Knowledge requirements of this competency

It may be appropriate to assess this unit concurrently with other relevant 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.

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 of 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 are covered by the shutdown. Where only a plant area is being shut (or one plant in an integrated complex), it also includes the impact of the shut on those areas still operating.

Reason for shut down

The reason for plant shut down may include:

planned shutdown for regulatory vessel inspections

major maintenance

catalyst or column regeneration/repacking

other activities requiring plant shutdown to access

Organisation systems

Organisation systems applications/data bases may include:

MAXIMO/SAP or other relevant work management tool as appropriate for area of responsibility

Scheduling tools such as MS Project, Excel, Gant Chart, Primavera or similar

other electronic recording / reporting software systems

paper based reports/record systems

Hazard identification tools

Hazard Identification tools may include but not be limited to:

hazard and operability studies (HAZOP)

hazard analysis studies (HAZAN)

job hazard/safety analysis (JHA/JSA)

safe work method statements (SWMS)

risk matrix

Activities intended for shutdown

Activities intended for shutdown may come from:

maintenance planning

process/production records

other sources

Resources required for task

Resources required for task include:

time

people

material

other

Resource requirements

Resource requirements may include but not limited to:

utility services such as steam, nitrogen, power, water, chemicals

workforce such as operators, maintenance, contractors, engineers, laboratory staff, safety observer, standby rescue crew

mobile equipment such as elevated work platforms, Hiab, vacuum trucks, drip trays

other equipment such as hoses, plugs and caps, scaffold, extra fire protection equipment

Shut down documentation

Shut down documentation include:

procedures

packages

isolation lists

blinds list

punch lists

Equipment preparation

Equipment preparation includes:

isolation

blinding/spading

purging

ventilation

washing

Communication

Communication includes:

preparations

overnight activities

progress

problems

potential delays

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.

Unit sector

Operational/technical

This unit contains employability skills.