Assessor Resource

FPPWEO440A
Troubleshoot and rectify wet end systems

Assessment tool

Version 1.0
Issue Date: December 2018


This unit applies to operators who troubleshoot and rectify wet end systems in the pulp and paper industry. This work typically involves complex integrated equipment and continuous operations

This unit generally applies to those who:

identify and analyse the causes of systems and quality faults

rectify systems, equipment faults

rectify product quality faults, and

record and report process performance and product quality data

to meet safety, quality and productivity requirements

It does not include monitoring and controlling, starting up or shutting down wet end operations

This unit describes the outcomes required to troubleshoot and rectify wet end systems in the pulp and paper industry

General legislation, regulatory, licensing and certification requirements applicable to this unit are detailed in the range statement

Specific high risk (and non-high risk) load shifting licensing requirements for this unit may be applicable and are to be met separately and prior to the achievement of this unit

You may want to include more information here about the target group and the purpose of the assessments (eg formative, summative, recognition)

Prerequisites

Not Applicable


Employability Skills

This unit contains employability skills




Evidence Required

List the assessment methods to be used and the context and resources required for assessment. Copy and paste the relevant sections from the evidence guide below and then re-write these in plain English.

The evidence guide provides advice on assessment and must be read in conjunction with the performance criteria, required skills and knowledge, range statement and the Assessment Guidelines for the Training Package.

Overview of assessment

Critical aspects for assessment and evidence required to demonstrate competency in this unit

Evidence should be relevant to the work. It should satisfy the requirements of the elements and performance criteria and include consideration of:

the required knowledge and skills tailored to the needs of the specific workplace

applicable OHS regulations, environmental and safe working requirements/practices, SOP and housekeeping requirements

applicable aspects of the range statement

practical workplace demonstration of skills in troubleshooting and rectifying wet end systems

Context of and specific resources for assessment

A workplace assessment must be used to assess:

the application of required knowledge on the job

the application of skills on the job, over time and under a range of typical conditions that may be experienced in wet end operations

Access to the full range of equipment involved in integrated continuous manufacturing wet end operations in a pulp or paper mill is required

Method of assessment

A combination of assessment methods should be used. The following examples are appropriate for this unit:

observation of applied skills and knowledge on the job

workplace demonstrations via a mock-up or simulation that replicate part/s of the job

answers to written or verbal questions about specific skills and knowledge

third-party reports from relevant and skilled personnel

written evidence e.g. log sheet entries, checklist entries, test results

Assessment processes and techniques must be culturally appropriate and in keeping with the language and literacy capacity of the learner and the work being performed. This includes conducting an assessment in a manner that allows thoughts to be conveyed verbally so that the learner can both understand and be understood by the assessor (e.g. use plain English and terminology used on the job)

A holistic assessment with other units relevant to the pulp and paper industry, mill and job role is recommended

Additional information on approaches to assessment for the pulp and paper industry is provided in the Assessment Guidelines for this Training Package


Submission Requirements

List each assessment task's title, type (eg project, observation/demonstration, essay, assingnment, checklist) and due date here

Assessment task 1: [title]      Due date:

(add new lines for each of the assessment tasks)


Assessment Tasks

Copy and paste from the following data to produce each assessment task. Write these in plain English and spell out how, when and where the task is to be carried out, under what conditions, and what resources are needed. Include guidelines about how well the candidate has to perform a task for it to be judged satisfactory.

This describes the skills and knowledge required for this unit.

Required skills

Identifies, accesses and interprets relevant historical and operational data and information

Uses required forms of communication in troubleshooting and rectifying wet end systems

Communicates effectively with personnel to assist with analysis and resolution of operational problems

Reads and interprets required documentation, procedures and reports

Accesses, navigates and enters computer-based information

Interprets instruments, gauges and data recording equipment

Identifies and actions systems, quality and equipment faults within level of responsibility

Assists others to identify and resolve operational problems in the workplace

Identifies causes and effects of faults and corrective action on associated processes

Selects and uses appropriate troubleshooting methods

Takes timely corrective action to maximise safety, quality and productivity

Undertakes necessary calculations to aid troubleshooting as required

Takes samples, conducts tests, interprets and records results

Uses measuring equipment as required

Maintains situational awareness in the work area

Operates high risk (and non-high risk) load shifting equipment as required

Analyses and uses sensory information to adjust process to maximise safety, quality and productivity

Uses electronic and other control systems to control equipment and processes as required

Required knowledge

Procedures, regulations and legislative requirements relevant to wet end operations including OHS, environmental including relevant sustainability requirements/practices, SOP, isolation procedures, safe working requirements, risks and hazard identification and housekeeping

Use and handling requirements of chemicals used; their purpose, effects, MSDS and SOP

Relevant forms of communication

Detailed knowledge of wet end plant, processes and associated services sufficient to troubleshoot including:

plant layout

theory of operation

causes and effects of adjustments made to wet end plant and processes

relationships between wet end plant, processes and associated services

An appropriate range of troubleshooting methods

Sampling and testing process for plant and system operations, and process monitoring - purpose, standards and procedures as per site agreements

Causes and effects of unplanned shutdown and appropriate responses

Mill maintenance system as it applies to wet end plant and processes

Application of high risk (and non-high risk) load shifting equipment as required

Sensory information that indicates a deviation from standard operating parameters

Sufficient knowledge of electronic and other control systems, operation and application to make appropriate adjustments that control wet end operations, within level of responsibility

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 italicised wording, if used in the performance criteria, is detailed below. 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) may also be included.

Productivity requirements may include:

energy efficiency

waste minimisation

evaporation minimisation, including landfill and waste water reduction

environmentally safe waste disposal

consideration of resource utilisation, including fibre efficiency

minimising delays

chemical recovery maximisation

meeting key performance indicators

line speed

handovers

quality checks

meeting output targets i.e. net tonnes per employee per annum

machine/process time availability i.e. time the machine or process is making product

machine/process production rate

Systems and functions in wet end operations may include:

stock approach systems

forming system

pressing systems

cleaning and screening system

Materials and supplies may include:

water

air

stock

chemicals

additives

steam

machine clothing

baled pulp

Equipment may include:

screens

forming section

water, chemical, vacuum or stock systems

former

pumps

consistency meter

flow meter

refiner

control valves

cleaning showers

chemical showers

presses

cleaners

waste hood recovery unit

computer systems

electronic screens and alarms

process control systems

fully automated, semi-automated, manually operated plant and equipment appropriate to the wet end process

Electronic control systems may include:

Digital Control System (DCS)

touch screens

robotics

Hazards and risks involved in wet end operations may include:

steam and/or gas leaks

fires

nip points

compressed air

hot surfaces

electrical

entanglement

vehicle movement

slip hazards/falls

energy

pressures

chemicals

fumes

confined spaces

dust

Legislation, regulatory, licensing and certification requirements may include:

OHS and environmental requirements (local, state and commonwealth)

activity or task specific high risk (and non-high risk) load shifting licensing requirements

Documentation, procedures and reports may include:

SOP

site policy and procedures

environmental sustainability requirements/practices

plant manufacturing operating manuals

confined space requirements

vendor documentation

reference manual

grade specifications

quality procedures

oil or chemical spills and disposal guidelines

plant isolation documentation

housekeeping

safe work documentation e.g. plant clearance, job safety analysis, permit systems

maintenance logs

job sheets

operating log

production instructions

Materials Safety Data Sheets (MSDS)

process and instrument diagrams

Maintenance may include:

operator level maintenance as per site agreements

operator maintenance schedules

maintenance systems

maintenance suppliers

pro-active maintenance strategies e.g. Total Productive Maintenance (TPM), Reliability Centred Maintenance (RCM)

Actions may include:

process adjustments

reporting to authorised person

rectifying problem within level of responsibility

Communications may include

interaction with:

team members

production/service co-ordinators

internal/external customers and suppliers

maintenance services

operational management

statutory authorities

Situational awareness may include

awareness of:

traffic

pedestrians

location of equipment

product

hazards

obstructions

unexpected movement

Sensory information may include:

visual

sound

feel

touch

smell

vibration

temperature

Forms of communications may include:

written e.g. log books, emails, incident and other reports, run sheets, data entry

reading and interpreting documentation e.g. standard operating procedures, manuals, checklists, drawings

verbal e.g. radio skills, telephone, face to face, handover

non-verbal e.g. hand signals, alarms, observations

signage e.g. safety, access

Copy and paste from the following performance criteria to create an observation checklist for each task. When you have finished writing your assessment tool every one of these must have been addressed, preferably several times in a variety of contexts. To ensure this occurs download the assessment matrix for the unit; enter each assessment task as a column header and place check marks against each performance criteria that task addresses.

Observation Checklist

Tasks to be observed according to workplace/college/TAFE policy and procedures, relevant legislation and Codes of Practice Yes No Comments/feedback
Causes of system and quality faults are identified and analysed within Occupational Health and Safety (OHS) regulations, environmental and safe working requirements/practices, Standard Operating Procedures (SOP), and housekeeping requirements 
Alarm systems and observations are interpreted to determine fault type and location 
Routine inspections of plant and processes are made to identify faults 
Sampling and testing results are interpreted to identify variations from operating parameters 
Cause and source of problem is identified and located 
Relevant sources of information are accessed and interpreted to assist analysis 
Information is communicated to relevant personnel 
Systems and equipment faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Equipment is shut down and isolated prior to fault rectification, if required 
Faulty equipment is by-passed where the process allows 
Faulty equipment is repaired or replaced as required 
Corrective adjustments are made to equipment 
Operator level maintenance is undertaken as required 
Restoration to normal operation is verified and communicated to relevant personnel 
Product quality faults are rectified within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Product quality faults or variations are identified by observation inspection and testing 
Samples for a range of tests are taken 
Test results are interpreted and processes are adjusted to correct variations from specification 
Process performance and product quality data is recorded and reported within OHS regulations, environmental and safe working requirements/practices, SOP, and housekeeping requirements 
Variations from specifications are documented 
Performance variations are documented 
Corrective actions are recorded 
Out-of-specification product is dealt with 
Information is communicated to appropriate personnel 

Forms

Assessment Cover Sheet

FPPWEO440A - Troubleshoot and rectify wet end systems
Assessment task 1: [title]

Student name:

Student ID:

I declare that the assessment tasks submitted for this unit are my own work.

Student signature:

Result: Competent Not yet competent

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Assessor name:

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Assessment Record Sheet

FPPWEO440A - Troubleshoot and rectify wet end systems

Student name:

Student ID:

Assessment task 1: [title] Result: Competent Not yet competent

(add lines for each task)

Feedback to student:

 

 

 

 

 

 

 

 

Overall assessment result: Competent Not yet competent

Assessor name:

Signature:

Date:

Student signature:

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