Assessor Resource

PMC553010C
Process raw meal into product

Assessment tool

Version 1.0
Issue Date: March 2024


This unit of competency applies to operators who are responsible for preparing and processing raw meal into cement and/or lime product.

This unit does NOT require the operation of a central control panel.

This competency is typically performed by an experienced operator, leading hand or supervisor. At all times they would be liaising and cooperating with other members of the team.

This unit of competency covers the preparation and processing (in a large plant) of raw meal through a kiln and distribution of the cement/lime product to storage. It involves conducting pre-start checks, operating and monitoring the process, rectifying operational problems and facilitating output changes.

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

Prerequisites

PMC552010C

Operate a calcining kiln


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

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.

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

It is essential that the process be understood and that the importance of critical material properties, settings and readings is known. Competence must be demonstrated in the ability to recognise and analyse potential situations requiring action and then in implementing appropriate corrective action.

Consistent performance should be demonstrated. In particular look to see that:

temperatures are maintained within limits

quality is monitored to minimise wastage

process measurements are continually made or observed.

Competence must be demonstrated in the operation of all ancillary equipment to the level required for this unit of competency.

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.

Assessment will occur over a range of situations which will include disruptions to normal, smooth operation.

Simulation or case studies/scenarios may be required to allow for timely assessment of parts of this unit of competency. Simulation should be based on the actual plant and will include 'walk-throughs' of the relevant competency components. A bank of scenarios/case studies/what ifs and questions will be required to probe the reasoning behind observable actions.

Method of assessment

In all plants it may be appropriate to assess this unit concurrently with relevant teamwork and communication units.

Individual enterprises may choose to add prerequisites and co-requisites relevant to their processes.

Guidance information for assessment

Assessment processes and techniques must be culturally appropriate and appropriate to the language and literacy capacity of the candidate and the work being performed.


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.

Required skills

Required skills include:

recognising variance from specifications and standard operating procedures and determining an appropriate action that is consistent with operating guidelines

implementing the enterprise's standard procedures and work instructions and relevant regulatory requirements within appropriate time constraints and in a manner relevant to the operation of the process

reading and numeracy to interpret workplace documents and technical information

Required knowledge

Required knowledge includes:

operation procedures of the kiln and kiln system

kiln chemistry, chemistry and physics of cement/lime making processes (as appropriate)

isolation procedures

operational processes and functions, including startup and shutdown processes

composition and nature of raw materials and finished product

construction and limitations of the equipment

out of specification situations

material feed, cooling and distribution systems

distinguish between causes of faults such as:

equipment fault

variations in raw materials

variations in feed rates and preparation

kiln quality and optimisation practices

types of kiln fuels and reactions

acceptable ranges of variations

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.

Procedures

All operations are performed in accordance with standard procedures and work instructions

Equipment and operations

Equipment and operations may include:

instrument panels (local)

measuring and recording equipment

communication equipment

hand tools

emergency stop buttons and lanyards

personal protective equipment

grinding mills

pneumatic conveying systems

slurry pumps

dust collectors

mixing and blending silos

vibrating screens

kilns

bulk storage silos

heat recovery systems

Typical problems

Typical problems may include:

equipment malfunctions

temperature fluctuations

quality of product

material/feed variations

spillages and leakages

inaccuracies in blending and proportioning of raw materials

out of specification moisture content of raw materials/slurry

variations in temperature, time and cooling rates

variations in feed rates or quantities

vibration

Occupational health and safety (OHS)

The identification and control of hazards and the application of OHS are to be in accordance with current, applicable legislation and regulations, and company procedures. All work is carried out at all times in accordance with these requirements

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
Notify/keep informed all relevant people about the current status operations and any intention to make changes 
Perform all pre-start checks in accordance with standard operating procedures 
Set up and configure equipment startup function complying with procedures 
Check plant/equipment settings against operating parameters as identified in standard operating procedures 
Load raw materials in accordance with work instructions 
Start up plant/equipment in accordance with procedures 
Commence/continue process operations in accordance with specified operating procedures 
Monitor and check against target parameters instrument/ control panels for variations, fluctuations or trends 
Maximise throughput of system while meeting quality target parameters 
Check and adjust ancillary equipment as required 
Monitor and perform necessary adjustments to discharge rate and temperature as required 
Monitor the distribution transport system for efficiency and spillages and take appropriate action as required 
Monitor the distribution of product to the correct storage area and level of product in that area, and redirect as required 
Identify possible routine and non-routine problems in the equipment or process 
Determine problems needing action 
Determine possible fault causes 
Rectify problem using appropriate solution within area of responsibility 
Follow through items initiated until final resolution has occurred 
Report problems outside area of responsibility to designated person 
Ensure line is clear of all product and left ready for startup 
Shut down equipment in accordance with procedures 
Complete appropriate records and logs 
Shut down equipment in an emergency situation 
Isolate equipment in accordance with procedures 
Remove any broken materials safely 
Ensure area is clear and safe for maintenance 
Identify hazards in kiln work area 
Assess the risks arising from those hazards 
Implement measures to control those risks in line with procedures and duty of care 

Forms

Assessment Cover Sheet

PMC553010C - Process raw meal into product
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

Feedback to student

 

 

 

 

 

 

 

 

Assessor name:

Signature:

Date:


Assessment Record Sheet

PMC553010C - Process raw meal into product

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:

Date: