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Scenario · Laboratory and Product Quality

Sample, test and adjust ferric chloride batch FC-26-0210

You are a laboratory technician in Laboratory and Product Quality working with the outside operator.

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The situation

What has happened

Reactor 2 is at the end of the reaction hold on ferric chloride batch FC-26-0210 and the panel operator is waiting for the laboratory result before the batch can be adjusted and transferred to tank T-206. Last week an outside operator was splashed while sampling because the glove cuff did not overlap the sleeve, so sampling protective equipment is under close attention. The specification for this grade sets iron content, free acid, specific gravity and insolubles bands. The first result usually needs a small acid or water adjustment, which the laboratory calculates and the panel operator applies before a resample. Patrick Nguyen wants the results in the shift log within 45 minutes of the sample arriving.

Your brief. Take the batch sample safely with the outside operator, test it to the methods, compare the results with the specification, calculate the adjustment required, advise the panel operator under the batch procedure, resample after adjustment and record the results and the release in the shift log.
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Tasks

Deliverables

  • Completed batch sheet with raw results and adjustment calculation
  • Shift log entries for the first sample, the adjustment advice and the resample
  • Sampling protective equipment check note
  • Batch release entry authorising transfer

Documents to use

Systems to use

Control Room Shift Log

Records every operating event, batch, reading, sample result, override and handover from the control room and the field for each shift.

Bulk Transfer and Tank Inventory Register

Records every receipt, internal transfer and dispatch of bulk product with tank, quantity, gauging and reconciliation.

For trainers and assessors

Units of competency

Current on training.gov.au for the Chemical, Hydrocarbons and Refining as at 10 September 2026.

PMAOPS319Adjust batch
PMAOPS220Monitor chemical reactions in the process
PMAOPS101Read dials and indicators
PMAOPS213Package product/material

Qualifications

PMA20116Certificate II in Process Plant Operations
PMA30120Certificate III in Process Plant Operations
Assessor notes

What to look for

Evidence guide

Look for the protective equipment checked and worn correctly before sampling, the sample point checked, results recorded as raw data with the method, an adjustment calculation that is shown and correct, advice given through the procedure rather than informally, and a resample before release. Shift log entries must be timely and complete.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.